Monolayer Particle Coating for Recirculating Print Carriers
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Solution Overview
Problem
Conventional film-coated carriers in printing processes are wasteful and expensive due to the inefficiency of using only a small proportion of the film coating, with most remaining on the carrier after printing.
Innovation Solution
A coating apparatus that applies a monolayer of particles to a recirculating receiving surface, regulated by a dosing device controlled by a sensor to maintain uniform particle concentration, using an air circulation loop with brushes and suction to ensure efficient particle application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If a conventional film-coated carrier is used in printing, then the printing process can be completed, but most of the film coating remains on the carrier after printing causing waste and expense
Solution Approach 1:
The patent implements a system where the intermediate transfer member (ITM) is continuously recycled through a coating apparatus that replenishes particles on its surface. The ITM circulates in a closed loop, and particles that are transferred to the substrate are recovered and reused on subsequent ITM cycles, eliminating the need to discard the carrier after single-use printing.
Solution Approach 2:
The patent creates a continuous circulation system where the ITM repeatedly passes through the coating apparatus to receive fresh particles, then travels to the printing station, transfers particles to the substrate, and returns to the coating apparatus. This continuous cycle ensures the ITM is always ready for the next printing operation without interruption or waste.
2Loss of substance
If a recirculating receiving surface is used with particle coating, then particle utilization efficiency is improved, but the system complexity increases due to coating apparatus, suction system, and circulation loop
Solution Approach 1:
The coating apparatus serves multiple functions: it applies particles to the ITM surface, removes excess particles via suction, and recirculates the particle-laden air back through the system. The suction system simultaneously removes untransferred particles and maintains negative pressure to prevent particle escape, consolidating multiple operations into integrated components.
Solution Approach 2:
The patent employs a pneumatic system where pressurized air carries particles from the coating apparatus to the ITM surface, and a suction system uses negative pressure to remove excess particles and recirculate the air-particle mixture through the circulation loop. This pneumatic approach replaces complex mechanical coating and removal mechanisms.
3Manufacturing precision
If a monolayer of particles is applied to the receiving surface, then coating uniformity is improved, but the dosing control precision must be extremely high to maintain consistent particle concentration
Solution Approach 1:
The patent incorporates sensors that continuously monitor particle concentration in the air stream and on the ITM surface. This feedback information is fed to a controller that adjusts the dosing device parameters in real-time to maintain optimal particle concentration, ensuring uniform monolayer formation despite variations in printing demand or environmental conditions.
Solution Approach 2:
The dosing device is designed to dynamically adjust particle delivery rates based on real-time conditions rather than operating at a fixed rate. The system can modulate dosing intensity to match varying print demands, ensuring consistent monolayer coating quality while adapting to changing operational requirements.
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 apparatus achieves a uniform and efficient coating of the receiving surface, reducing waste and ensuring consistent print quality by recycling particles and adapting to varying print demands.
Implementation Method 1
a source of pressurised air for supplying the dosing device with air (under pressure) having suspended within it the particles to be used in coating the receiving surface
Implementation Method 2
using an air circulation loop with brushes and suction to ensure efficient particle application
Implementation Method 3
using an air circulation loop with brushes and suction to ensure efficient particle application
Data Source
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AI summary
The disclosure relates to a coating apparatus for applying a monolayer layer of particles to a receiving surface. The apparatus comprises a pressurized air source, an application chamber partially bounded by the receiving surface into which an air stream is delivered by the air source, an air return path for returning air from the application chamber to an intake of the air source to form an air circulation loop, a dosing device for introducing particles to be coated onto the receiving surface into the air circulation loop, and a controller serving to regulate the dosing device so as to maintain the particle concentration within predetermined limits. A method of applying a layer of particles is also provided, as well as printing systems benefiting from the present coating apparatus.