Inline Ultrasonic Ink Degassing and Particle Reduction
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Solution Overview
Problem
Conventional printing systems face issues with gas compression and nozzle clogging due to resident gases and particulates in ink, which affect the reliability of inkjetting and lead to costly material loss, and existing vacuum degasification systems are complex and do not address all solid particles.
Innovation Solution
Incorporating an ultrasonic module within the ink delivery system to apply ultrasonic energy for degassing and reducing particle size, using ultrasonic probes or baths to condition the ink, allowing for efficient removal of gases and management of particulates, thereby enhancing inkjetting reliability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If vacuum degasification is used to remove gases from ink, then gas removal effectiveness is improved, but device complexity increases due to requirement of vacuum sources or pressure sources
Solution Approach 1:
The patent replaces the mechanical vacuum degasification system with an ultrasonic field-based system. The ultrasonic module generates cavitation bubbles through acoustic waves, which collapse to create localized high-pressure zones that effectively remove gases from ink without requiring vacuum pumps or pressure sources, thus eliminating complex mechanical components while maintaining gas removal effectiveness
Solution Approach 2:
The patent changes the physical parameter approach from mechanical pressure differential (vacuum) to acoustic energy (ultrasonic frequency and intensity). By controlling ultrasonic parameters such as frequency, power, and exposure time, the system achieves gas removal through cavitation and acoustic streaming effects, providing a simpler alternative to vacuum systems
2Reliability
If vacuum degasification is used to remove gases from ink, then gas removal is achieved, but the system cannot address particulate matter and agglomerated particles
Solution Approach 1:
The ultrasonic module serves multiple functions simultaneously: it removes gases through cavitation, breaks down agglomerated particles through mechanical shear forces, and disperses particulate matter through acoustic streaming. This single device replaces multiple separate treatment systems, providing both gas removal and particle management capabilities
Solution Approach 2:
The ultrasonic module employs high-frequency mechanical vibrations to achieve both gas removal and particle treatment. The vibrational energy creates cavitation bubbles for gas removal while simultaneously generating shear forces that break down particle agglomerates and disperse particulates, addressing both issues through a unified mechanical vibration mechanism
3Reliability
If conventional vacuum degasification systems are used, then gases are removed from ink, but the systems are complex and require additional hardware
Solution Approach 1:
The patent replaces the mechanical vacuum degasification system with an ultrasonic field-based system. The ultrasonic module generates cavitation bubbles through acoustic waves, which collapse to create localized high-pressure zones that effectively remove gases from ink without requiring vacuum pumps or pressure sources, thus eliminating complex mechanical components while maintaining gas removal effectiveness
Solution Approach 2:
The ultrasonic module utilizes the ink's own properties to facilitate gas removal. The cavitation process naturally occurs within the ink medium itself, using the liquid's compressibility and bubble formation characteristics to achieve degassing without external mechanical assistance, making the system self-sufficient and hardware-minimal
4Productivity
If no particle size reduction is applied, then ink can be jetted as is, but larger particles cause nozzle clogging and print head failure
Solution Approach 1:
The ultrasonic module performs preliminary particle size reduction and dispersion treatment on the ink before it reaches the print head. By breaking down agglomerates and dispersing particulates in advance, the system prevents nozzle clogging before it occurs, ensuring reliable inkjetting operation without requiring post-treatment or maintenance interventions
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
The ultrasonic treatment effectively degasses the ink, reduces particle size, and prevents nozzle clogging, improving the reliability and efficiency of inkjetting, reducing material loss, and enabling the use of a wide range of ink types without the need for vacuum degasification hardware.
Implementation Method 1
ultrasonic energy has previously been used to break down kidney stones in a medical environment
Implementation Method 2
ultrasonic energy is applied to the ink, such as at a sufficient level and duration to degas the ink
Implementation Method 3
sonication has been used previously in applications other than printing, to break down larger particles into smaller particles
Implementation Method 4
the applied energy is configured to reduce the size of the agglomerates to a size that can be jetted through the print head
Data Source
AI summary
Enhanced printing systems, structures, and processes provide ultrasonication of ink, such as to degas the ink, and/or to maintain the size of particles within the ink. At least one ultrasonic module, such as comprising any of an ultrasonic probe or an ultrasonic bath, is located within an ink delivery system. Ink is delivered to the ultrasonic module, and ultrasonic energy is applied to the ink, such as at a sufficient level and duration to degas the ink, and/or to reduce the size of particles within the ink. In some embodiments, the particles may be agglomerates, wherein the applied energy is configured to reduce the size of the agglomerates to a size that can be jetted through the print head. In other embodiments, the particles may be metallic particles, wherein the applied energy is configured to create smaller metallic particles that can be jetted with the ink through the print head.