Ink Leveling Device Using Thermal Gradient Control

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Solution Overview

Problem

Certain inks, such as UV curable gel ink, become viscous and sticky after application, leading to undesirable 'corduroy' structures and excessive seepage into porous substrates, which affects image quality and curing efficiency.

Innovation Solution

A contactless ink leveling method is employed, creating a steep thermal gradient across the substrate by heating the ink above its viscosity threshold while maintaining the substrate below this threshold, using steam or hot air to prevent ink penetration into the substrate, and employing a thermal gradient to allow ink flow without significant seepage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If the ink is heated above its viscosity threshold to enable ink flow and leveling, then the ink can flow smoothly, but the ink penetrates significantly into the porous substrate

Engineering Contradiction:

Improveink leveling qualityVSAvoidink seepage into substrate

Core Design Contradiction:

Manufacturing precisionVSLoss of substance

Solution Approach 1:

The patent applies different temperature conditions to different locations: the ink surface is heated above the viscosity threshold to enable flow, while the substrate is maintained below the threshold to prevent excessive ink penetration. This spatial differentiation of temperature zones allows simultaneous achievement of ink leveling and substrate protection.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The thermal field is segmented into distinct zones: a heating zone that raises the ink temperature above the viscosity threshold for flow, and a cooling zone that maintains the substrate temperature below the threshold to prevent seepage. This segmentation enables independent control of ink flow and substrate absorption characteristics.

Inventive Principle:

Principle #1Segmentation

2Ease of operation

If a contactless method is used to level the ink, then the substrate is not physically touched, but controlling the thermal gradient precisely is more difficult

Engineering Contradiction:

Improvecontactless levelingVSAvoidthermal gradient control

Core Design Contradiction:

Ease of operationVSDifficulty of detecting and measuring

Solution Approach 1:

The patent controls the thermal gradient by adjusting key parameters including the temperature of the heating element, the temperature of the cooling element, the relative positioning of these elements, and the duration of thermal treatment. These parameter changes enable precise control of the ink leveling process while maintaining contactless operation.

Inventive Principle:

Principle #35Parameter changes

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

This method effectively levels the ink without penetrating the substrate, maintaining image quality and enabling complete curing by keeping the ink in a gel state near the surface, preventing excessive seepage and ensuring efficient ink flow.

Implementation Method 1

heating the ink above its viscosity threshold temperature

Methodology Applied

Scientific EffectViscosity-temperature relationship:

Implementation Method 2

maintaining the substrate below this threshold

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Implementation Method 3

creating a steep thermal gradient across the substrate

Methodology Applied

Scientific EffectThermal gradient: Temperature Gradient

Data Source

PatentUS8991997B2Device for leveling ink under a thermal gradient

Publication Date: 2015.03.31 XEROX CORP

AI summary

An ink leveling device for controlling a temperature difference across a substrate having ink disposed on the upper surface, the device including a cooling device cooling a bottom of a substrate to a first temperature that is lower than a viscosity threshold temperature of the ink, a heating device heating the upper surface of the ink layer to a second temperature that is greater than the viscosity threshold temperature of the ink and a device applying shear force across the upper surface of the ink layer.