LUMA specializes in the production of high-quality Tungsten wire for a variety of industrial applications, including its use as a charge wire. Charge wires play a crucial role in creating fields of positive and negative charges that generate electrostatic fields, which are integral to devices such as digital printers, air ionizers, and electrostatic separators. Tungsten wire, with its superior strength, durability, and adaptability, is an ideal choice for this demanding application.
The LUMA wire is warp-knitted directly by LUMAs customers or by other sub-suppliers, into so-called mesh which is a kind of net. The warp-knitting process is kind of a combination between weaving and sewing. The demands are high on uniformity and consistency of the wire, for example concerning dimension and tensile strength. The size of the mesh is in many cases large; from 1,5 meters in diameter to over 20 meters. For example an antenna can, when deployed, have the measurements of 19 meters * 17 meters, while packed, the size is 1 meter * 4 meters. In spite of its size, the net or mesh is light weight, with an accurate and repeatable deployable surface shape, still showing stiffness and robust mechanization that leads to reliability.
The warp-knitting process itself is very demanding and requires a lot of Know How from the textile industry. The control of the technologies related to mesh cutting, joining, tensioning and shaping is critical.
LUMA gold plated molybdenum wire is relatively light weight and has a highly elastic behavior. Light weight is an absolutely decisive factor for all products used in space. At the same time molybdenum has a non-linear stiffness and a very good thermal stability. The wire dimension normally used is between 20 and 40 micron. The wire performance withholds thermal, radiation, micrometeorite, UV and atomic oxygen environments.
The gold layer which is usually minimum 1% of the total dimension of the wire protects the wire against corrosion and enhances the RF (Radio Frequency) characteristics when reflecting signals which hit the mesh.
The technique of the warp-knitting process, the load and expected lifespan of the antenna, puts high demands on the LUMA wire supplied. The accuracy of the LUMA production process and final quality controls, have made LUMA one of the world’s preferred suppliers to this application area.
A charge wire operates by generating electrostatic fields through the application of high voltage. This field of positive and negative charges enables various industrial processes, including:
In all these applications, Tungsten wire is prized for its ability to withstand the intense demands of high-voltage cycles while maintaining its structural and functional integrity over time.
Digital printing technology involves complex electrostatic processes, as elegantly summarized in the novel Game Changer by Douglas E. Richards:
“Imagine sending a document to a laser printer… The computer instructs the printer drum to discharge a precise pattern of negative electrical energy matching every letter. The drum then attracts positively charged toner, which adheres to the negatively charged pattern. When the toner-coated drum transfers the toner onto paper, heated rollers melt it, producing a perfect copy of the document.”
While newer generations of digital printers have shifted away from wire-based technology, older models still rely on this proven system. Manufacturers like LUMA continue to supply charge wires to support these devices during their remaining operational lifecycle, although this application is gradually declining as technology evolves.
One prominent use of LUMA Tungsten wire is as a corona wire in professional digital printers. The corona wire creates fields of positive charges, which are essential for transferring toner to paper in a precise and consistent manner. Tungsten’s high melting point and resistance to wear make it an ideal material for these high-demand cycles of charge and discharge.
The use of gold-plated Tungsten wire in this application further enhances performance. The gold coating reduces defects, improves print quality, and prevents corrosion, thereby increasing the longevity of the printer’s components. The setup typically involves placing parallel wires in a frame, where electrical current is applied to create the magnetic field required for printing.
LUMA Tungsten wires are also used in air ionizers, devices designed to enhance air quality by creating charged air molecules. These molecules attract airborne particles like dust and pollen, which are then filtered out of the air.
Tungsten charge wires are vital in these systems due to their ability to handle the high voltage required to generate negative ions. These ions attach to positively charged particles, neutralizing them and allowing for effective filtration. Such devices are commonly used in:
While Tungsten wires remain indispensable in many current applications, technological advancements are gradually replacing wire-based systems in certain sectors, such as professional digital printing. However, the durability, versatility, and exceptional physical properties of Tungsten ensure its continued relevance in other industrial segments, including air purification and electrostatic processes.
Through its commitment to innovation and quality, LUMA continues to supply high-performance Tungsten wires that meet the demanding needs of manufacturers across various industries. Whether improving air quality or enabling precision printing, Tungsten charge wires stand as a testament to LUMA’s expertise in material science and advanced manufacturing.
Luma Wire Tech AB
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