Laser Diode Dryer for Coated Substrates in Aqueous Ink Printers
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Solution Overview
Problem
Current aqueous ink printing systems face challenges in efficiently drying images on coated substrates without increasing the complexity, energy consumption, or substrate temperatures, as existing dryers inadequately remove water and solvents from ink images on these substrates.
Innovation Solution
A new aqueous ink printing system incorporates a dryer with variably controlled laser diodes and a controller that adjusts the intensity of the laser diodes based on ink coverage density and substrate speed, ensuring efficient drying without significant complexity or temperature increases by targeting specific areas of the image with varying energy levels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional uniform drying stages are added to improve drying effectiveness on coated substrates, then drying quality is improved, but device complexity and energy consumption increase
Solution Approach 1:
The patent applies local quality by varying the drying energy intensity across different regions of the substrate based on ink coverage density. The controller divides the substrate into multiple zones and applies different power levels to laser diodes in each zone, ensuring that areas with higher ink coverage receive more drying energy while areas with lower coverage receive less, thereby achieving uniform drying quality without adding multiple drying stages.
Solution Approach 2:
The patent implements dynamics by making the drying energy intensity adjustable and variable rather than uniform and static. The controller dynamically modifies the power output of laser diodes based on real-time detection of ink coverage density in different zones, allowing the drying system to adapt to varying ink distributions across the substrate without increasing device complexity.
2Manufacturing precision
If multiple uniform drying stages are added to remove sufficient water and solvents, then drying effectiveness is improved, but energy consumption increases
Solution Approach 1:
The patent applies local quality by directing drying energy selectively to areas where it is most needed based on ink coverage density. Zones with high ink coverage receive higher energy intensity, while zones with low coverage receive reduced energy, eliminating the need for multiple uniform drying stages and significantly reducing overall energy consumption while maintaining drying effectiveness.
Solution Approach 2:
The patent applies partial action by providing drying energy only to the extent necessary for each specific zone rather than applying excessive uniform energy across the entire substrate. This prevents energy waste in areas that require minimal drying while ensuring adequate drying in high-ink zones, thereby achieving effective drying with reduced energy consumption.
3Manufacturing precision
If drying temperature is increased to improve solvent removal, then drying effectiveness is improved, but substrate degradation and heat retention occur
Solution Approach 1:
The patent applies local quality by controlling the temperature distribution across different zones of the substrate according to ink coverage density. High-ink zones receive higher localized heating to ensure complete solvent removal, while low-ink zones receive reduced heating, preventing overall substrate temperature from reaching degradation levels and reducing heat retention in the output stack.
Solution Approach 2:
The patent implements dynamics by continuously adjusting the heating intensity in each zone based on ink coverage detection, rather than applying a static high temperature across the entire substrate. This dynamic control ensures that sufficient heat is applied locally where needed for solvent removal while preventing excessive heat accumulation that would cause substrate degradation.
4Productivity
If high temperatures are applied to uncoated substrates for brief periods, then drying speed is improved, but coated substrates require longer exposure or higher temperatures which cause degradation
Solution Approach 1:
The patent applies local quality by tailoring the drying temperature and exposure time to the specific ink coverage density in each zone of coated substrates. This allows the system to achieve effective drying of high-ink areas without subjecting the entire substrate to excessively high temperatures or prolonged exposure, thereby maintaining drying speed while preventing substrate degradation.
Solution Approach 2:
The patent implements dynamics by adjusting drying parameters in real-time based on detected ink coverage patterns. The system dynamically modifies heating intensity and exposure duration for each zone, enabling fast drying where ink coverage is high while reducing heat exposure in low-ink areas, thus achieving high productivity without harmful thermal effects on coated substrates.
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 approach enables efficient drying of aqueous ink images on coated substrates, reducing energy consumption and maintaining image quality, while minimizing the lengthening of the printer footprint and avoiding excessive substrate heating.
Implementation Method 1
a dryer having a plurality of laser diodes that are configured to be variably controlled
Implementation Method 2
enable the dryer to remove solvents from the ink images
Data Source
AI summary
A dryer for use in an aqueous ink printer adequately dries coated substrates printed with aqueous ink images before discharge of the substrates. The dryer has a housing, a plurality of laser diodes, a current source, a variable electrical resistance network having a plurality of resistors, and a controller. The controller is configured to identify a plurality of ink coverage densities for a plurality of areas in an ink image that passes through the dryer, select and vary an electrical resistance of one or more of the resistors in the variable electrical resistance network using the identified ink coverage densities, and operate the plurality of resistors in the variable electrical resistance network to connect the laser diodes in the dryer selectively to the current source through the plurality of resistors using the identified ink coverage densities and a speed of the substrate through the dryer.