Phase Change Ink Leakage Detection Using Thermal Sensing
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Solution Overview
Problem
Inkjet printers face downtime due to ink leakage from heated conduits, which is difficult to detect using traditional sensor technologies, especially for phase change inks that are electrically non-conductive and thermally hot.
Innovation Solution
A printing apparatus with a temperature sensing device, such as a resistive thermal device (RTD), is positioned to detect changes in temperature caused by leaked heated phase change ink, triggering an annunciator to alert for leaks, thereby minimizing downtime and repairs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional sensor technologies are used to detect ink leakage, then the detection system is simple and inexpensive, but the detection capability is insufficient for phase change inks that are electrically non-conductive and thermally hot
Solution Approach 1:
The patent replaces traditional electrical or optical sensors with a temperature sensing device that detects thermal changes. The temperature sensor monitors temperature changes in the housing caused by leaked heated phase change ink, providing reliable detection without requiring complex electrical or optical sensing systems. This substitution of detection mechanism resolves the contradiction by achieving reliable detection capability through a simpler thermal sensing approach rather than complex electrical/optical sensor systems.
2Productivity
If ink leakage is not detected, then the system operates continuously, but printer downtime increases due to unexpected leaks requiring repairs and cleaning
Solution Approach 1:
The patent implements preliminary detection action by positioning the temperature sensing device to detect temperature changes before significant ink leakage occurs. The sensor is strategically placed in the housing where leaked ink would contact it, enabling early warning that allows for preventive maintenance and minimizes unexpected downtime. This preliminary detection capability resolves the contradiction by enabling continuous operation with early leak detection, preventing the need for emergency repairs and associated downtime.
3Measurement precision
If the temperature sensing device is positioned to detect leaked ink, then detection accuracy is improved, but the device complexity increases due to positioning requirements and housing modifications
Solution Approach 1:
The patent applies local quality by positioning the temperature sensing device at a specific location in the housing where leaked ink is most likely to contact the sensor. The housing is modified with a specific structural feature (such as a channel or recess) that directs leaked ink toward the sensor. This localized approach resolves the contradiction by achieving high detection accuracy through strategic positioning rather than requiring complex positioning systems or extensive housing modifications throughout the entire device.
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 solution effectively detects ink leaks in the printhead module, reducing printer downtime by accurately sensing temperature changes from leaked ink and activating an alarm, ensuring timely maintenance.
Implementation Method 1
a temperature sensing device configured to sense a change in temperature in response to a leaked heated phase change ink contacting the temperature sensing device
Implementation Method 2
The temperature sensing device is positioned at a location in the housing where gravity can direct the leaked heated phase change ink into contact with the temperature sensing device
Implementation Method 3
a heated conduit having a first end and a second end. The first end of the heated conduit is operatively connected to the inlet of the printhead and the second end is operatively connected to the source of ink to carry the heated phase change ink from the source of ink to the printhead
Data Source
AI summary
A printing apparatus includes a printhead module having an ink leakage detector to detect a leaked phase change ink. The ink leakage detector includes a plurality of resistance temperature detectors or resistive thermal devices to detect the leaked phase change ink. A horizontally mounted overdriven thermistor can also be used to detect leaked ink.