Solid Ink Stick Top Surface Conditioning for Planarity
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for manufacturing solid ink sticks, such as the flow fill process, result in poor height control and stress cracks due to uneven cooling, and are unable to form visually recognizable symbols on the top surface, leading to handling and operational issues.
Innovation Solution
A system comprising a molten ink delivery station and a top surface conditioning station that includes a press plate or laser writing station to form and condition the top surface of solid ink sticks, ensuring planarity and the ability to create visually recognizable symbols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the flow fill process is used to manufacture solid ink sticks, then the manufacturing speed and cost effectiveness are improved, but the height control and top surface planarity deteriorate
Solution Approach 1:
The patent applies preliminary action by introducing a top surface conditioning station that performs surface planarization and symbol formation while the ink material is still in a semi-solid or molten state, before complete solidification occurs. This preliminary conditioning ensures proper height control and surface flatness without compromising manufacturing speed
Solution Approach 2:
The patent utilizes parameter changes by controlling the temperature and viscosity of the ink material during the conditioning process. By maintaining the ink in a semi-solid or molten state during top surface conditioning, the material remains pliable enough to be formed and marked, then solidifies afterward to retain the conditioned shape
2Ease of manufacture
If the flow fill process is used to manufacture solid ink sticks, then the manufacturing cost is reduced, but the occurrence of stress cracks and breaking increases
Solution Approach 1:
The patent applies preliminary action by conditioning the top surface while the ink material is still pliable (semi-solid or molten state), before complete solidification. This timing allows the material to be formed without stress cracks, and then it solidifies to retain the stress-free conditioned shape
Solution Approach 2:
The patent exploits phase transitions by utilizing the semi-solid or molten state of the ink material during top surface conditioning, then allowing it to solidify afterward. This phase transition approach enables forming operations without causing stress cracks, as the material transitions from a pliable state to a solid state after conditioning
3Device complexity
If the open top of the forming tub is used during manufacturing, then the manufacturing process is simplified, but the top surface planarity and symbol formation capability deteriorate
Solution Approach 1:
The patent applies preliminary action by introducing a top surface conditioning station that performs surface planarization and symbol formation while the ink material is still in a semi-solid or molten state, before complete solidification occurs. This preliminary conditioning ensures proper height control and surface flatness without compromising manufacturing speed
Solution Approach 2:
The patent utilizes parameter changes by controlling the temperature and viscosity of the ink material during the conditioning process. By maintaining the ink in a semi-solid or molten state during top surface conditioning, the material remains pliable enough to be formed and marked, then solidifies afterward to retain the conditioned shape
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 system achieves improved height control and top surface planarity, enabling the formation of solid ink sticks with visually recognizable symbols, reducing the likelihood of handling issues and enhancing operational reliability.
Implementation Method 1
The forming section includes at least one press plate for contacting and controllably forming, which can include substantially flattening, the top surface of the ink material
Implementation Method 2
The component dyes and carrier composition are heated to their liquid state and then poured into a tub... the outer layer of the molten ink and carrier radiate heat to the outside air and cool more quickly than the interior portions of the mixture
Implementation Method 3
the top surface conditioning station or a marking station comprises a laser writing station including a laser for providing a laser beam for ablating the visually recognizable symbol into the top surface of the material in the forming tubs
Data Source
AI summary
A system is provided for forming solid ink sticks comprising a molten ink delivery station for introducing molten ink material into a forming tub to form a solid ink stick. The forming tub includes an open top for receiving the molten ink material and a cavity defining a lower portion of a solid ink stick shape. The system includes a top surface conditioning station for altering the top surface of the ink material introduced into the cavity of the forming tub.