Ink Injector Fuel Rail for High-Speed Web Printing
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Solution Overview
Problem
High-speed web printing systems face inefficiencies due to high ink flow demands, leading to internal head pressure fluctuations and interruptions in the printing cycle, as traditional ink jet printing technologies struggle to maintain consistent ink delivery at high speeds.
Innovation Solution
Employing ink injectors similar to automotive fuel injectors, with modified aperture plates and a controlled ink supply system, including a pump and controller, to deliver ink at high pressure and flow rates while minimizing pressure surges and ink atomization, and using thermal expansion relief in ink delivery tubes to maintain consistent ink flow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high ink flow rate is used to match fast web movement, then productivity is improved, but internal head pressure fluctuations occur causing printing interruptions
Solution Approach 1:
The ink supply system pre-pressurizes and pre-delivers ink to the print head reservoirs before the printing cycle begins. The pump system maintains ready supply of ink at controlled pressure, so when the print head fires, ink is already positioned and pressurized for immediate ejection, eliminating delays and pressure fluctuations during actual printing
Solution Approach 2:
The system incorporates a reservoir that acts as a cushion between the pump and print head. This reservoir absorbs pressure surges and provides a buffer supply of ink, preventing pressure fluctuations from reaching the print head during high-speed operation, thereby maintaining printing cycle continuity
2Productivity
If high pressure ink delivery is used to maintain ink flow at high speeds, then productivity is improved, but pressure surges and ink atomization occur
Solution Approach 1:
The patent introduces an intermediary reservoir system between the high-pressure pump and the print head. The reservoir receives ink at high pressure from the pump but releases it at controlled, lower pressure to the print head. This intermediary buffer eliminates pressure surges and prevents ink atomization while maintaining high delivery speed capability
Solution Approach 2:
The system changes the pressure parameter through the ink delivery path. The pump operates at high pressure to ensure rapid ink supply, but the reservoir and delivery mechanism transform this to controlled lower pressure at the print head, optimizing both speed and preventing harmful pressure effects
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures efficient and uniform ink delivery at high speeds, maintaining production levels of 500 to 1000 pages per minute without interruptions, extending the life of print heads and improving filter life by managing pressure and flow rates effectively.
Implementation Method 1
deliver ink at high pressure and flow rates while minimizing pressure surges
Implementation Method 2
using thermal expansion relief in ink delivery tubes to maintain consistent ink flow
Data Source
AI summary
A print head has an array of jets to transfer ink from the print head to a printing substrate, at least one ink supply rail to provide ink, and at least one injector to deliver ink from the ink supply rail to the print head. A printer has at least one supply to provide ink, at least one print head to transfer ink onto a printing substrate, an ink supply rail to provide ink to the print head, and an injector to deliver ink from the ink supply rail to the print head. A printing system has an array of print heads, each having at least one injector, at least one ink supply rail to deliver ink to the print heads, at least one supply to supply ink to the ink supply rail, and a transport system to transport a web substrate past the array of print heads.