Ink Jet Printer Air Separator Plate Arrangement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Continuous ink jet printers face issues with air separation from ink, leading to disrupted ink jet formation, nozzle blockages, and incorrect printing due to air bubbles and particulate matter, which existing filters cannot effectively address.
Innovation Solution
An arrangement comprising a series of overlapping plates within an ink tank, where the ink/air mixture flows across the surfaces of the plates, allowing air bubbles to separate and aggregate, with a gap of 2 mm to 5 mm between plates and textured surfaces to enhance bubble interaction and separation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a filter is used to remove particulate matter from ink, then printing quality is improved, but air bubbles cannot be effectively removed and may pass through the filter
Solution Approach 1:
The ink return path is divided into multiple sequential separation stages using multiple plates (first plate, second plate, third plate) with gaps between them. Each plate creates an individual separation zone, and the cumulative effect of multiple stages achieves both particulate removal and air bubble separation that a single filter cannot accomplish
Solution Approach 2:
The plates act as intermediary elements between the ink return line and the ink tank. These plates create controlled interfaces where air-ink separation occurs through the gaps, serving as a mechanical mediator that physically separates air bubbles from the ink stream before ink is recirculated
2Productivity
If suction is applied to the gutter line to convey ink away from the gutter, then ink collection efficiency is improved, but air is entrained into the ink mixture
Solution Approach 1:
The air that is harmful when entrained in the suction line is converted into a beneficial separation mechanism. The air-ink mixture is deliberately directed to flow over plates with gaps, where the air bubbles naturally rise and separate in the gaps, transforming the harmful air entrainment into an effective air separation process
Solution Approach 2:
The separation process moves from a one-dimensional flow path to a multi-dimensional approach by creating vertical gaps between horizontal plates. Air bubbles utilize the vertical dimension to rise and separate from the horizontal ink flow, adding a spatial dimension to the separation process that enhances air removal while maintaining ink collection efficiency
3Reliability
If air remains in the ink when returned to the ink gun, then ink jet formation is disrupted and nozzle blockages occur, but adding separation arrangements increases device complexity
Solution Approach 1:
The plates serve multiple functions simultaneously: they act as flow distributors to ensure even ink flow across the tank, create separation zones for air bubble removal through their gaps, and function as structural support elements within the ink tank. This multi-functionality achieves reliable air separation without proportionally increasing device complexity
Solution Approach 2:
The arrangement enables continuous recirculation of ink while discarding (removing) air bubbles and particulate matter. The separated air is vented from the system while the cleaned ink is recovered and returned to the ink gun, creating a sustainable closed-loop system that maintains ink jet stability
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
Effectively separates air from ink, reducing bubble-related issues in the ink jet printer, ensuring stable ink flow and improved printing quality by minimizing air bubbles and particulate matter, thus preventing nozzle blockages and maintaining ink jet integrity.
Implementation Method 1
ink that has been received by the fluid inlet flows onto an upper surface of the first plate and flows across at least a part of the upper surface... a space below the plate portion for receiving ink that has passed over at least the first plate
Implementation Method 2
textured surfaces to enhance bubble interaction and separation... allowing air bubbles to separate and aggregate
Implementation Method 3
textured surfaces to enhance bubble interaction and separation... allowing air bubbles to separate and aggregate
Data Source
Figure 1~3
Figure 4
Figure 5
AI summary
An ink/air separator for an ink jet printer has one or more plates (77, 79, 81, 83) over which an ink/air mixture can spread. Preferably there is more than one plate, and the mixture overflows from one plate to the next. Preferably adjacent plates are spaced so that as the mixture passes between two plates it contacts the surface above it as well as the surface below it. The plates may be separated by a gap of 10 mm or less, e.g. a gap of 2 mm to 5 mm, where they overlap Preferably some or all of the plate surfaces contacted by the mixture are roughened. Interaction between the ink/air mixture and the plate surface tends to slow the flow of very small air bubbles and encourage them to accumulate and/or merge, so that they separate from the ink more quickly than individual small bubbles. The ink/air separator may be connected in the path of unused ink returned from the gutter (27) of a continuous ink jet printer to an ink tank (39), or may be placed inside the ink tank (39).