Spring Metal Emission Tips for Corona Discharge Safety
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing high-voltage electrodes with rigid emission tips protruding minimally from insulating encapsulation suffer from reduced electric field strength, increased corona usage, lower discharge efficiency, and safety risks due to proximity to grounded machine parts, leading to higher operating voltages and production costs.
Innovation Solution
Designing emission tips as spring metal elements that can protrude freely from the carrier body, forming an elastic spring configuration to maximize electric field strength while minimizing mechanical resistance and incorporating a high-impedance series resistor for safe operation, with optional air support for enhanced ionization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If emission tips protrude far from the insulating encapsulation to maximize electric field strength, then discharge efficiency improves, but safety risk increases due to proximity to grounded machine parts
Solution Approach 1:
The emission tips are designed as spring elements that can dynamically adjust their position. They protrude far from the insulating encapsulation during normal operation to maximize electric field strength and discharge efficiency, but can elastically retract when approaching grounded machine parts, thus maintaining both high productivity and safety.
2Object-affected harmful factors
If emission tips protrude minimally from the insulating encapsulation for safety, then safety risk decreases, but electric field strength at the tips reduces
Solution Approach 1:
The spring element allows the emission tip to maintain a large protrusion distance during normal operation, ensuring high electric field strength. When safety concerns arise (proximity to grounded parts), the spring automatically reduces the protrusion, thus dynamically balancing energy efficiency and safety.
3Ease of manufacture
If rigid emission tips are used with minimal protrusion, then manufacturing simplicity is maintained, but corona usage increases significantly
Solution Approach 1:
The spring element enables the emission tip to protrude far from the encapsulation, which significantly reduces corona usage. The manufacturing process remains relatively simple as it only requires forming the spring element from conductive material and attaching it to the encapsulation, maintaining ease of manufacture while dramatically improving energy efficiency.
4Use of energy by moving object
If spring metal emission tips are used to protrude freely, then electric field strength maximizes, but device complexity increases due to elastic spring configuration
Solution Approach 1:
The spring element can be designed with appropriate material properties (conductive spring metal) and geometric parameters (coil diameter, pitch, wire thickness) to achieve the desired protrusion distance and elasticity. By optimizing these parameters, the device achieves maximum electric field strength while keeping the spring configuration as simple as possible.
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 free-standing spring tips reduce corona usage by up to 30%, increase discharge efficiency, lower operating voltages, and ensure safe handling with reduced risk of injury, while also reducing the need for high-pressure auxiliary air and minimizing production costs.
Implementation Method 1
In the presence of an electric field, the highest possible electric field strength should be effective in an arrangement of emission tips of active and passive high-voltage electrodes at the tips
Implementation Method 2
the carrier body (7) made of an insulating material, which has at least one high-impedance series resistor (13)
Implementation Method 3
The term corona use describes the voltage at which free charge carriers, i.e. electrons and ions of both polarities, are generated in front of the peaks by impact ionization
Implementation Method 4
the gas between the tips and the charged object surface becomes conductive
Data Source
Figure 1~3
AI summary
The invention relates to an emission tip assembly (100) on high-voltage electrodes for charging or discharging substrates, comprising at least one emission tip (1) and a carrier body (7) composed of an insulating material, which has at least one high-resistance series resistor (13), wherein the at least one emission tip (1) can be connected to a high-voltage connection (14) by means of the series resistor (13). In order to have available an assembly of emission tips which, despite protrusion from the carrier body (7) thereof to any extent in principle and despite the metal profiled element (10, 10a) provided with the insulating potting mass (6), causes no injuries in the event of unintentional and intentional contact and thus permits safe handling together with high efficiency of the assembly, the emission tip (1) is formed of a spring metal and forms an elastic spring element, and a free end of the emission tip (1) is freely spaced apart from the carrier body (7), the particular metal profiled element (10, 10a), and the insulating potting mass (6), as a corona tip (2). In addition, the range effect of a discharge electrode is improved by the guiding of an auxiliary air quantity (15) directly to the corona tip (2).