System and method for positioning a print head of a printing device

Abstract

Systems and methods for printing on a polymeric film web are disclosed in which first and second adjacent print head carriages are slidably disposed on at least one track, and a protrusion extends from the first print head carriage toward the second print head carriage. A linear actuator operates to cause the print head carriages to move between a first position in which the protrusion contacts the second print head carriage, and a second position in which the protrusion is not in contact with the second print head carriage, and the first print head carriage and the second print head carriage are separated by a predetermined distance.

Description

[0001] Cross-references to related applications This application claims priority to U.S. Provisional Patent Application Serial No. 63 / 293,189, filed December 23, 2021, entitled “SYSTEMS AND METHODS FORPOSITIONING PRINTHEADS OF A PRINTING APPARATUS”. The entire contents of that application are incorporated herein by reference. Technical Field

[0002] The subject matter disclosed herein relates to printing apparatus, and more particularly to a printing apparatus including a system and method for positioning a printhead of the printing apparatus. Background Technology

[0003] High-speed printing systems have been developed for printing on substrates such as webs of heat-shrinkable polymer films. These materials typically exhibit both elastic and plastic properties, depending on one or more applied influences, such as force, heat, chemicals, electromagnetic radiation, etc. The material deposited on the web by the imaging unit of the printing system is usually dried before additional material is deposited by subsequent imaging units. Some webs (such as heat-shrinkable polymer films) begin to shrink, deform, or otherwise become damaged when heated above a critical temperature. The drying of one or more materials deposited on such webs must be monitored and controlled so that sufficient heat is applied to dry the deposited material without raising the web temperature above a critical temperature.

[0004] The above discussion is provided only for general background information and is not intended to be used to help determine the scope of the claimed subject matter. Summary of the Invention

[0005] According to one aspect, a system for printing on a polymer film web includes: at least one track; a linear actuator; first and second adjacent printhead supports slidably disposed on the at least one track; and a protrusion extending from the first printhead support toward a second printhead support. Operation of the linear actuator causes the printhead supports to move between a first position and a second position, in which the protrusion contacts the second printhead support, and in a second position, the protrusion does not contact the second printhead support, and the first and second printhead supports are separated by a predetermined distance.

[0006] According to another aspect, a method for printing on a polymer film web includes: slidably arranging first and second adjacent printhead supports on at least one track; and operating a linear actuator to move the first printhead support and the second printhead support between a first position and a second position, wherein in the first position a protrusion extending from the first printhead support contacts the second printhead support, and in the second position the protrusion does not contact the second printhead support, and the first printhead support and the second printhead support are separated by a predetermined distance.

[0007] According to a further aspect, a system for printing on a transparent polymer film web at a specific resolution includes a web transport member, a first printhead, and a second printhead. The web transport member transports the web along a processing direction. The first printhead has a first nozzle plate having a first nozzle and a first side edge, wherein there are no nozzles between the first nozzle and the first side edge. The second printhead has a second nozzle plate facing the web and having a second side edge and a second nozzle, wherein there are no nozzles between the second nozzle and the second side edge. Additionally, the second side edge is parallel to and close to the first side edge. The first nozzle and the second nozzle are separated by a nozzle pitch determined by the specific resolution along a width direction perpendicular to the processing direction, and the first side edge and the second side edge are separated by a distance greater than one nozzle pitch along the width direction.

[0008] Other aspects and advantages will become apparent when considering the following detailed description and accompanying drawings, in which similar numbers throughout the specification denote similar structures.

[0009] This brief description of the invention is intended only to provide a concise overview of the subject matter disclosed herein based on one or more illustrative embodiments, and is not intended as a guide for interpreting the claims or for defining or limiting the scope of the invention, which is defined only by the appended claims. This brief description is provided to present illustrative choices of concepts in a simplified form, which will be further described in the detailed description below. This brief description is not intended to identify key or essential features of the claimed subject matter, nor is it intended to serve as an aid in determining the scope of the claimed subject matter. The claimed subject matter is not limited to embodiments that address any or all the disadvantages pointed out in the background art. Attached Figure Description

[0010] To understand the features of the invention, a detailed description of the invention can be obtained by referring to certain embodiments, some of which are illustrated in the accompanying drawings. However, it will be noted that the drawings illustrate only certain embodiments of the invention and are therefore not intended to limit its scope, as the scope of the invention encompasses other equally effective embodiments. The drawings are not necessarily drawn to scale, and the emphasis is generally placed on the features illustrating certain embodiments of the invention. In the drawings, similar numerals are used throughout the various views to indicate similar parts. Therefore, for a further understanding of the invention, reference can be made to the following detailed description, which is taken in conjunction with the accompanying drawings: Figure 1 , Figure 2 and Figure 3 Various isometric views of embodiments of a module for printing one or more substances on a flexible substrate, wherein several parts are omitted; Figure 4 yes Figure 1 Enlarged, partial isometric view of the embodiment shown; Figure 5 It is roughly along Figure 1 A sectional view taken from line 5-5; Figure 6 It is roughly along Figure 1 A sectional view taken from line 6-6; Figure 7 yes Figure 1 The side elevation view of the two modules, from which several parts are omitted; Figure 8 It is a block diagram of a global controller that integrates various devices of the printing system, including the main ink reservoir, ink supply system, printing unit and dryer, and the interconnections therebetween. Figure 9 yes Figure 8 A block diagram of the multiple parts of the global controller; Figure 10 It is an isometric bottom view of the printhead and associated printhead holder that can be used in any module described herein; Figure 11 yes Figure 10 A bottom elevation view of the bottom surface of the printhead; Figure 12 yes Figure 1 A bottom elevation view of the printing module; Figure 13 It is roughly along Figure 12 A magnified bottom-view elevation view of the printing module, taken from line 13-13; Figure 14 It is shown Figure 11 A magnified view and schematic diagram of the alignment of adjacent printheads in the printing module, showing both a bottom view and a front view. Figure 15 yes Figure 10 A side elevation view of another embodiment of the printing module; Figure 16 It is roughly along Figure 15 An isometric view of the printing module, captured by line of sight 16-16; Figure 17 It is roughly along Figure 15 The isometric view of the printing module captured by line of sight 17-17; Figure 18 It is roughly along Figure 15 A cross-sectional view of the printing module taken from line 18-18; Figure 19A It is in the operating position Figure 15 A side elevation view of the printing module, which is shown with fewer printheads and some components are omitted for clarity; Figure 19B It is in maintenance mode. Figure 15 A side elevation view of the printing module, which is shown to have fewer printheads and some components are omitted for clarity; Figure 20 This shows the printhead transport controller for use in separate... Figure 19A and Figure 19B Movement between the operating position and the maintenance position shown Figure 15 A flowchart of the steps performed by the printing module; Figure 21 yes Figure 1 An isometric top view of another embodiment of the printing module, which is shown with certain elements omitted for clarity; Figure 21A yes Figure 21 Detailed view of part 21A-21A, with the linear actuator of the printing module in the extended position; Figure 21B It is roughly along Figure 21 A cross-sectional view taken from line 21B-21B; Figure 22 yes Figure 21 A bottom elevation view of the printing module; Figure 23 This is a side elevation view of a printhead holder, which has a printhead disposed therein, and the printhead can be used for... Figure 21 In the printing module; Figure 24 yes Figure 23 A bottom elevation view of the printhead support and a portion of the printhead; Figure 25 yes Figure 23A side elevation view of a portion of the printhead support; Figure 25A yes Figure 25 Side elevation view of the stop of the printhead bracket; Figure 26 yes Figure 23 Top-view isometric view of the printhead holder and printhead; and Figure 27 yes Figure 21 Top-down isometric view of the printing module. Detailed Implementation

[0011] A flexible substrate 22 in web form (e.g., a thermoplastic polymer material) passes through one or more printing modules and receives ink, which is dried to obtain a printed web. This printed web can be further processed to form printed individual units (such as bags). The bags can be adapted to receive one or more items therein. More specifically, Figure 8 and Figure 9 The diagram illustrates a global controller 110 operable to control various components described below, and... Figure 1-7 An embodiment of module 200, responding to global controller 110 and optionally other devices, is illustrated, wherein module 200 prints an aqueous substance on flexible substrate 22. (Note that, for clarity, ...) Figure 1-7 (Some pipes and fluid conduits are omitted from the illustration). Printing module 200 includes one or more printing units 201, each printing unit including one or more inkjet printheads 202 (see details). Figure 5 The illustrated embodiment includes four controllers 203a-203d, each associated with and operating one of the four printheads 202a-202d. The printing module 200 further includes an ink supply device, such as an ink supply unit from... Figure 8 and Figure 9 The main ink reservoir 205a shown receives ink from one or more ink supply units 205; the dryer system 204 includes one or more dryers (best seen) Figure 6The global controller 110 controls the continuous movement of substrate 22 at a throughput rate of, for example, at least 500 feet per minute. The substrate may alternatively be transported at a faster or slower throughput rate (e.g., 1000 feet per minute) as desired. The global controller 110 responds to one or more sensors and controls substrate transport 212, ink supply units(s) 205, printheads 202 (controlled via controller 203), and dryer system 204. The global controller 110 may also control additional components and may be implemented by one or more appropriately programmed computer-based devices, each including, for example, desktop or laptop computers, devices using one or more application-specific integrated circuits (ASICs) and / or field-programmable gate arrays (FPGAs), tablet computers, smartphones, and / or combinations thereof. The global controller 110 may be a single unit or may be distributed across one or more networks. Figure 9 As seen, the global controller 110 is connected to a local and / or network interface, such as a keyboard, mouse, monitor, touchscreen, local area network (LAN), wide area network (WAN) (such as the Internet), etc. The global controller 110 responds to commands supplied to it by the user via the local and / or network interface.

[0012] In addition to the above, the printing module 200 may also include, as needed and / or as desired, one or more structural elements that provide support for various conduits and other components, as well as enclosures that provide space to accommodate the various components.

[0013] like Figure 6 Specifically, as seen in the diagram, the dryer system 204 includes a first dryer group 220, a second dryer group 222, and a third dryer group 224. Dryer groups 200, 222, and 224 respectively include dryers 220a-220d, 222a-222d, and 224a-224j. Figure 6 These dryers are arranged sequentially in the figure according to the order of substrate movement. Some or all of dryers 220a-220d, 222a-222d and / or 224a-224j may include one or more dryer components (such as heaters and / or blowers), or may simply include passive ducts or radiators, and may be connected to inlet duct groups 225a-225c ( Figure 1 ) receives dryer air and can pass through exhaust duct assembly 226a-226c ( Figure 2Air is discharged. The dryer system 204 further includes a first rotatable roller 227 and a second rotatable roller 228 respectively disposed opposite to groups 222 and 224. Rollers 227 and 228 control substrate tension. Further, rollers 230a-230g (some or all of these rollers may include driven rollers or idler rollers) are arranged sequentially according to the order in which the substrate moves through the dryer system 204, such as... Figure 6 As seen in the text.

[0014] The dryer is controlled to dry the ink applied to the substrate 22 in a manner that minimizes substrate deformation as much as possible.

[0015] Printing unit 201 is located at operator-accessible print station 250. For example... Figure 6 As seen in the figure, the printing station 250 includes one or more idler rollers or driven rollers 230d-230f arranged sequentially in the order of substrate movement. The one or more idler rollers or driven rollers transport the substrate through the printing units 201 opposite the printhead 202. These printheads operate to deposit water-based ink onto one side 22a of the substrate 22 to achieve simplex printing.

[0016] Figure 7 The illustration shows one of them. Figure 6 The embodiment shown depicts two printing modules 200 disposed within a frame 270, which provides space for one or two operator control modules. (It can be noted that the frame 270 may form part of or be associated with one or two modules, or may be separate from the two modules. Moreover, for clarity, Figure 7 The printhead 202 and its associated controller are not shown in the image. Figure 6 and Figure 7 Some of the reference numerals for the visible elements in both are in Figure 7 (Not shown in the image.) More specifically, the first module 200a and the second module 200b (each module identical to module 200) are arranged in a spaced-apart relationship within the frame 270 to form the printing system 271. (See from...) Figure 7 As should be apparent, modules 200a and 200b are printed serially on substrate 22. Frame 270 includes one or more idler rollers and / or driven rollers 272a and 272b that transport the substrate 22 through frame 270 and between modules 200a and 200b. In the illustrated embodiment, rollers 272a and 272b are arranged sequentially along the direction of substrate movement. Figure 7 In the middle. Therefore, as Figure 7 What I saw and also referenced Figure 6The substrate enters module 200a and passes over / around rollers 230a-230c of module 200a, and subsequently passes over rollers 230d-230f in print station 250 of module 200a. During its journey from roller 230d to roller 230f, printhead 202 deposits water-based ink onto surface 22a of the substrate. The deposited ink can be any single color or combination thereof, including C (cyan), M (magenta), Y (yellow), K (primary color, i.e., black), O (olive), V (violet), G (green), S (spot color), white, clear or other primers, UV (ultraviolet), magnetic inks, etc. In an embodiment, module 200a prints clear primer and / or white panels and other printed content on successive portions of substrate 22 at 1200 dpi or any other resolution.

[0017] After ink is applied, the substrate 22 traverses the rollers 230g-230i of module 200a and passes through the first dryer assembly 220 of this module. The first stage of the dryer system 204 presents the printed surface 22a of the substrate 22 towards the dryer system 204, which includes dryers 220a-220d, which are operated as pinning devices to initiate the drying process. Figure 6 As seen, substrate 22 travels to roller 227 and then via roller 230j to roller 228, and then substrate 22 is guided by rollers 230k-230n and exits module 220a. As should be apparent, surface 22a is presented sequentially to the second and third stages of dryer system 204, including dryers 222a-222d and 224a-224k, respectively, to complete the drying process.

[0018] like Figure 7 As shown, the substrate continues to reach module 200b on rollers 272a and 272b, where surface 22a of substrate 22 receives further printed content, as described above in conjunction with module 200a. As described above, the printed content on surface 22a is dried by dryer unit 204 of the second module 200b. The printed substrate can be transported out of frame 270 for further processing, printing, finishing, and / or storage, as needed or desired.

[0019] In an embodiment, Figure 7Module 200b prints up to four “colors” (as described above) on surface 22a of the flexible substrate 22. Therefore, for example, module 200b can print, for example, C, M, Y, and / or K, at a resolution of 1200 dpi or any other resolution registered with successive portions of the substrate 22 printed by module 200a. In a further example, module 200a can print the primary process colors C, M, Y, and K at any resolution on successive portions of the substrate 22, and module 200b can print secondary process colors O, V, G, and optional spot color S, registered with and / or combined with the primary process colors C, M, Y, and K, on ​​the same surface 22a of the substrate 22. Alternatively, in this embodiment, it may be advantageous and / or desirable, as needed or desired, for both modules 200a and 200b to print primary and / or secondary printing colors or any other identical or different "(multiple) colors" at the same or different resolutions (registered or unregistered).

[0020] To print more colors or at different resolutions, additional printheads and associated printhead controllers and ink supply units can be added to modules(s) 200a, 200b. Alternatively, [the following can be done] Figure 7 Downstream of module 200b, a rotary bar other substrate reversing device (not shown) is provided, and one or two or more additional modules identical to module 200 may be provided downstream of the rotary bar or other substrate reversing device to allow duplex printing in four or eight or more “colors” on the surface 22b of substrate 22.

[0021] In addition to the above, as needed or desired, module 200 may also include one or more structural elements that provide support for various conduits and other components, as well as enclosures that provide space to accommodate the various components.

[0022] refer to Figure 10 and Figure 11 In one embodiment, each printhead 500 (which may be the printhead 202 described above or another printhead) disposed in the printhead holder 502 of the print unit 201 of the print module 200 includes a printhead housing 504 and an ink chamber 506. The ink chamber 506 includes one or more ink supply ports 508, which can be connected to an ink source (not shown) via a corresponding ink supply line (not shown).

[0023] The printhead 500 includes a bottom portion 510 having a bottom surface 512. The printhead 500 is disposed in a printhead holder 502 such that the bottom surface 512 faces the substrate 22. The bottom portion 510 (and therefore the bottom surface 512) is defined by a first side edge 516, a second side edge 518, a front edge 520, and a rear edge 522. Additionally, the bottom portion 510 includes a nozzle plate 524 having a plurality of nozzles 526 disposed between a first side edge 528 and a second side edge 530 of the nozzle plate 526. During printing, as the substrate 22 is conveyed through these nozzles 526, ink in the ink chamber 506 is ejected from one or more of the plurality of nozzles 526 disposed in the nozzle plate 524.

[0024] In some embodiments, the first side edge 516 and the second side edge 518 of the bottom surface 512 are substantially parallel, and the front edge 520 and the rear edge 522 of the bottom surface 512 are substantially parallel.

[0025] In some embodiments, the first side edge 516 of the bottom surface 512 includes a first side edge portion 532a, a first side edge 528 of the nozzle plate 524, and a second side edge portion 532b, all of which are substantially collinear. Similarly, the second side edge 518 of the bottom surface 512 includes a first side edge portion 534a, a second side edge R126 of the nozzle plate 524, and a second side edge portion 534b, all of which are also collinear.

[0026] In some cases, the first side edge 516, the second side edge 518, the front edge 520, and the rear edge 522 of the bottom surface 512 define a perimeter 514 of the bottom surface 512. In some embodiments, this perimeter 514 is a parallelogram, wherein the first side edge 516 forms an oblique angle with the front edge 520 and the rear edge R118, and the second side edge 518 also forms an oblique angle with the front edge 520 and the rear edge 522. It will be apparent to those skilled in the art that the perimeter 514 can have different shapes, including, for example, different polygons (squares, rectangles, hexagons, etc.) or even shapes having one or more non-linear segments.

[0027] Figure 12 An embodiment of a printing module 200 is shown, which includes a printing unit 201 comprising a plurality of printheads 500, each of which is configured to deposit a specific fluid (e.g., primer, ink of a specific color, coating material, etc.) onto the substrate 22 through a plurality of nozzles 526 as the substrate 22 moves along a processing direction 538.

[0028] The printhead 500, including the printing unit 201, is fixed to one or more printhead supports 502. Specifically, one or more of the printheads 500, including the printing unit 201, are fixed to each printhead support 502. Figure 12 As shown, for example, printheads 500a to 500d are fixed to printhead holder 502a, printheads 500e to 500h are fixed to printhead holder 502b, and so on. The printhead 500, including the printing unit 201, and the printhead holder 502 to which such printhead 500 is fixed, are configured such that the plurality of nozzles 526 of the printhead 500 (see...) Figure 11 Extends 536 along the width of the fabric.

[0029] Also refer to Figure 13 In one embodiment, the printhead 500 is configured such that the leading edge 520 of the printhead disposed in each holder 502 is offset relative to each other along the processing direction 538. Therefore, as Figure 13 As illustrated, printheads 500a to 500e in printhead holder 502a are offset relative to each other, and printheads 500f to 500i in printhead holder 502b are also offset relative to each other, and so on. Since the side edges 516, 518 of adjacent printheads 500 in each printhead holder 502 are not parallel to the processing direction 538, this offset of the printheads 500 creates a gap 540 between adjacent printheads 500 along the width direction 536 without affecting the distance between adjacent nozzles 526 of the plurality of nozzles 526 in the adjacent printheads 500 along the web width direction 536. This gap 540 prevents excessive fluid droplets ejected by the printhead 500 from entering and drying between the sidewalls of adjacent printheads 500, prevents debris from becoming stuck between the sidewalls, allows cleaning fluid to enter the gap 540, dislodges and thus flushes away any ink and / or debris, and facilitates the removal of one printhead 500 disposed in the holder 502 without impacting or otherwise contacting adjacent printheads 500 disposed in the holder 502.

[0030] In some embodiments, each printhead holder 502 is also offset relative to another adjacent holder 502 along the processing direction 538. As a result, the printhead 500 disposed in one printhead holder 502 (e.g., printhead 500d disposed in printhead holder 502a) and the adjacent printhead 500 disposed in another printhead holder 502 (e.g., printhead 500e disposed in printhead holder 502b) are also offset relative to each other along the processing direction 538. The printhead holders are offset in such a way that a gap 542 is formed along the width direction between the first printheads 500d, 500h, 500l, 500p or 500t respectively disposed in the first printhead holders 502a, 502b, 502c, 502d or 502e and the second printheads 500e, 500f, 500i, 500q or 500u respectively disposed in the second printhead holders 502b, 502c, 502d, 502e or 502f, wherein the first printheads and the second printheads are adjacent to each other and disposed in adjacent printhead holders 502. In addition to the reasons described above for having a gap 540 between adjacent printheads 500 in the same printhead holder 502, having a gap 542 between adjacent printhead holders 502 also facilitates the removal of printhead holders 502 from the printing module 200 without the risk of a printhead 500 in such a printhead holder 502 accidentally coming into contact with or colliding with another printhead 500 in an adjacent printhead holder 502.

[0031] In some embodiments, the printhead holder 502 is fixed to the mounting rod 543 ( Figure 12 A support column and mounting bracket (not shown) are disposed between and secured to the printhead bracket 502 and the mounting rod 543.

[0032] Figure 14 The illustration further illustrates the relationship between the first and second adjacent printheads 544, 546 (identical to printhead 500 described above) and their respective first nozzles 548 and second nozzles 550, wherein the first nozzles 548 and second nozzles 550 are adjacent to each other (i.e., the first nozzles 548 and second nozzles 550 are operable to deposit adjacent fluid droplets onto the substrate 22 along the web width direction 536). The first printhead 544 represents any one of printheads 500a to 500w, and the second printhead 546 represents any one of printheads 500b to 500x adjacent to printheads 500a to 500w respectively (in... Figure 12 (As shown in the figure). Note that the arrangement of the first printhead 544 and the second printhead 546, as well as the first nozzle 548 and the second nozzle 550, is shown schematically for illustrative purposes.

[0033] It should be apparent that, since the first nozzle 548 of the first printhead 544 is adjacent to the second nozzle 550 of the second printhead 546, there are no other nozzles of the first printhead 544 between the first nozzle 548 and the first side edge 516. Similarly, there are no other nozzles of the second printhead 546 between the second nozzle 550 and the second side edge 518. Furthermore, to ensure that there are no obvious discontinuities or other unwanted artifacts between the first and second adjacent portions of the images printed by the first printhead 544 and the second printhead 546 respectively, the distance 552 along the width of the web between the first nozzle 548 and the second nozzle 550 should be equal to the distance between the plurality of nozzles 526 of the first printhead 544 and the second printhead 546 (see...). Figure 11 The nozzle pitch (i.e., the distance between nozzles that deposit adjacent drops of another fluid onto the substrate 22) is substantially the same. That is, for example, if the first printhead 544 and the second printhead 546 are 1200 dots / inch printheads, then the nozzle pitch of the plurality of nozzles 526 of such first printhead 544 and second printhead 546 is approximately 0.00083 inches (0.021 mm). In this case, the distance 552 between the first nozzle 548 of the first printhead 544 and the second nozzle 550 of the second printhead 546 should also be approximately 0.00083 inches (0.021 mm). It will be apparent to those skilled in the art that this nozzle pitch varies depending on the resolution of the first printhead 544 and the second printhead 546 being used.

[0034] like Figure 14 As illustrated, offsetting the first printhead 544 and the second printhead 546 along the processing direction 538 by a distance 554 increases the space between the first side edge 516 of the bottom surface 512 of the first printhead 544 and the second side edge 518 of the bottom surface 512 of the second printhead 546. As the offset along the processing direction 538 increases, the distance 556 along the width direction (i.e., the gap 540 or 542 discussed above) increases accordingly. If the offset along the processing direction 538 is large enough, the distance 556 exceeds the distance 552 between the first and second adjacent nozzles 548 and 550. That is, the distance 556 exceeds the nozzle pitch of the plurality of 526 of the first printhead 544 and the second printhead 546. If the first printhead and the second printhead print at different resolutions, the distance 556 along the web width direction 536 exceeds the distance 552 (i.e., the nozzle pitch) between the first nozzle 548 and the second nozzle 550 along the web width direction 536.

[0035] In some embodiments, adjacent first printheads 544 and second printheads 546 located in the same printhead holder 502 are offset along the processing direction 538 such that the distance 554 between the rear edge 522 of the bottom surface 512 of the first printhead 544 and the rear edge 522 of the bottom surface 512 of the second printhead 546 is between approximately 0.0846 inches and 0.1034 inches, and in an embodiment approximately 0.094 inches (2.38 mm). Further, adjacent first printheads 544 and second printheads 546 located in adjacent printhead holders 502 are offset along the processing direction 538 such that the distance 554 between the rear edge 522 of the bottom surface 512 of the first printhead 544 of one holder 502 and the rear edge 522 of the bottom surface 512 of the second printhead 546 in the adjacent holder 502 is preferably between approximately 0.3096 inches and approximately 0.3784 inches, and in an embodiment preferably approximately 0.344 inches (8.74 mm).

[0036] In some embodiments, the gap 540 between adjacent printheads 500 in the same bracket 502 results in a spacing (when measured along a direction perpendicular to such sidewalls) between approximately 0.0342 inches and approximately 0.0418 inches, and in an embodiment approximately 0.038 inches.

[0037] In some embodiments, the gap 542 between adjacent printheads 500 of adjacent brackets 502 results in a spacing (when measured along a direction perpendicular to such sidewalls) between adjacent sidewalls 516, 518 of adjacent printheads 500 disposed in adjacent brackets 502 between approximately 0.0954 inches and approximately 0.1166 inches, and preferably approximately 0.106 inches in an embodiment.

[0038] It will be apparent to those skilled in the art that increasing or decreasing the distance 554 between the rear edges 522 of the first printhead 544 and the second printhead 546 increases or decreases the distance 556 between adjacent sidewalls 516, 518 of the first printhead 544 and the second printhead 546, respectively. For example, in some embodiments, the distance 554 between the rear edges 522 of the bottom surface 512 of the first printhead 544 and the rear edges 522 of the bottom surface 512 of the second printhead 546 is preferably between approximately 0.0594 inches and 0.0726 inches, and in one such embodiment, it is approximately 0.066 inches. In this embodiment, the gaps 540, 542 between the first printhead 544 and the second printhead 546 cause the distance 556 between adjacent sidewalls 516, 518 of the first printhead 544 and the second printhead 546 along the width direction to be between approximately 0.0297 inches and 0.0363 inches, and in one such embodiment, it is approximately 0.033 inches.

[0039] In some embodiments, the printhead 500 disposed in the printing unit 201 is a Samba G3L and / or Samba G5L printhead sold by Fujifilm Dimatix, Inc. of Santa Clara, California. It will be apparent to those skilled in the art that different printheads, still having a first side edge 516 and a second side edge 518 that are not parallel to the processing direction 538, can be used in the printing unit 201. Further, the printing unit 201 can be configured to use other printheads, wherein such other printheads adjacent to each other have bottom surfaces that overlap along the processing direction, while the prints produced by the adjacent printheads are seamed.

[0040] Figures 15 to 19A Figure 19B illustrates another embodiment 600 of the printing module 200. (See reference...) Figure 15-19A 19B, the printing module 600 includes a first printing unit 602 having a first plurality of printhead supports 604a to 604x slidably mounted along a first side 606 of a central block 608. A printhead 500 can be secured to a corresponding one of the first plurality of printhead supports 604. For clarity, Figure 15 Only the printhead 500 disposed in printhead holders 604a and 604x is shown, while printhead holders 604b to 604w are shown as not having printhead 500.

[0041] The printhead supports 604a to 202x and the printhead 500 to which they are fixed are configured such that the plurality of nozzles 526 of the printhead 500 (see...) Figure 11The printheads extend along the width direction 536 of the substrate. Thus, each of the printheads 500 fixed in the printhead holder 604 is operable to deposit a first specific fluid (e.g., primer, ink of a specific color, coating material, etc.) onto the substrate through its plurality of nozzles 526 as the substrate 22 moves along the processing direction 538.

[0042] In some embodiments, the printing module 600 includes a second printing unit 610 comprising a second plurality of printhead supports 612 slidably mounted on a second side 614 of a central block 608, and a printhead 500 is fixable to each of the second plurality of printhead supports 612. In this embodiment, the printhead supports 612 are configured such that the plurality of nozzles 526 of the printheads 500 disposed in the printhead supports 612 extend along a web width direction 536. Each of the printheads 500 disposed in the printhead supports 612 is operable to deposit a second fluid onto a substrate through its printhead nozzles 526 as the substrate 22 moves continuously along a processing direction 538. Although the first fluid and the second fluid are typically different, it will be apparent to those skilled in the art that the printheads 500 disposed in the first plurality of printhead supports 604 and the printheads disposed in the second plurality of printhead supports 612 may be operable to deposit the same fluid (e.g., for overprinting or other applications apparent to those skilled in the art). It should be apparent that the printing module 200 may be configured with as many printhead supports 612 (and thus printheads 500) as needed, such that the nozzles 526 of the printheads 500 disposed in such printhead supports 612 span the substrate 22 along the width direction 536 to print an image with a desired width.

[0043] Each printhead holder 612 includes a front plate 616 and a rear plate 618 fixed to each other. The front plate 616 includes a mounting device 620 to which the printhead 500 can be fixed.

[0044] First linear support block 622 (see...) Figure 18 A first linear support block 622 is fixed to the rear plate 618 of each printhead holder 612. A first linear support block 622 of each printhead holder 612 is slidably disposed on a first linear support track 624 fixed to a center block 608. In some embodiments, a second linear support block 626 is fixed to the rear plate 618 of each printhead holder 612, and the second linear support block 626 is slidably disposed on a second linear support track 628 also fixed to the center block 608.

[0045] Similarly, each of the second plurality of printhead supports 604 is mounted on the center block 608 by a corresponding first linear support block 218a mounted on the first linear support rail 624 and (optionally) a second linear support block 626 mounted on the second linear support rail 628.

[0046] In some embodiments, one or more spacing and alignment members 629 may be disposed between the front plate 616 and the rear plate 618 to adjust the distance along the processing direction 538 between the front plate 616 and the first side 606 of the center block 608 and / or the angle between the front plate 616 and the first side 606 of the center block 608. It will be apparent to those skilled in the art that adjusting the distance and / or angle between the front plate 616 and the first side 606 of the center block 608 of the printhead holder 604 also adjusts the distance and / or angle between the front plate 616 and the first side 606, and between the printhead 500 disposed in such a printhead holder 604 and the first side 606. The distance and / or angle between each of the second plurality of printhead holders 612 and the second side 614 of the center block 608 can be adjusted in a similar manner.

[0047] like Figure 15 As shown, the first printing unit 602 includes printhead supports 604a to 604x, which are fixed to a first side 606 of the central block 608 and distributed along the web width direction 536. In this embodiment, printhead supports 604a and 604x are terminal printhead supports, and printhead supports 604b to 604w include intermediate printhead supports disposed therebetween.

[0048] In some embodiments, the extendable arm 630 of the linear actuator 632 is secured to the terminal printhead holder 604a. In some embodiments, the terminal printhead holder 604x is secured to the extendable arm 630 of another linear actuator 632a, such as... Figure 15 and 16 As shown in the image.

[0049] In other embodiments, the terminal printhead holder 604x is fixed to a fixing block 634, which is fixed to a first side 606 of the center block 608 (e.g., Figure 19A and Figure 19B (As shown in the diagram). The fixing block 634 provides an anchor to prevent the terminal printhead support 604x from moving along the first support rail 624.

[0050] Similarly, one of the terminal printhead holders 612 fixed to the second side 614 of the center block 608 is fixed to the extendable arm 636 of another linear actuator 636, and the other of the terminal printhead holders 612 fixed to the second side 614 of the center block 608 is fixed to another fixing block (not shown).

[0051] As described in more detail below, the printhead holder 604 of the print module 200 is movable between an operating position (i.e., a printing position) and a maintenance position. When in the operating position, the printhead holder 604 is arranged such that a predetermined gap exists between adjacent bottom surfaces 512 of printheads 500 disposed in printhead holders 604 adjacent to each other along the web width direction 536. This gap depends on the resolution of the adjacent first and second printheads 500 disposed in the printhead holders 604. Specifically, the predetermined gap is selected such that the distance between a first nozzle in the plurality of nozzles 526 of the first printhead 500 disposed in the first printhead holder 604 and a second nozzle in the plurality of nozzles 526 of the second printhead 500 disposed in the adjacent second printhead holder 604 coincides with the nozzle pitch of the plurality of nozzles of the first and second printheads 500. In some embodiments, the predetermined gap between the sidewalls 516, 518 of adjacent printheads is between approximately 0.0117 inches and 0.0143 inches, and preferably approximately 0.013 inches.

[0052] When the first printhead holder 604 is moved from the operating position to the maintenance position, each of the printhead holders 604 moves a predetermined amount along the first linear support rail 624 and the second linear support rail 628 in a direction parallel to the web width direction 536, such that this printhead holder 604 (and the printhead 500 disposed therein) is sufficiently spaced from the adjacent printhead holder 604 (and the printhead 500 disposed therein). This spacing facilitates cleaning between the printheads 500 to remove ink and / or debris trapped between adjacent printheads 500 or printhead holders 604 and to remove the printheads 500 disposed in the printhead holders 604 without contacting the adjacent printhead holders 604. In some embodiments, when in the maintenance position, this predetermined gap between the sidewalls 516, 518 of adjacent printheads is between approximately 0.054 inches and 0.066 inches, and preferably approximately 0.066 inches.

[0053] Figure 19A and Figure 19B This is a simplified schematic diagram of the printing unit 602, illustrating the movement of the printhead support 604 between an operating position and a maintenance position. For clarity, Figure 19A and Figure 19B A printing unit 602 with only four printhead supports 604a to 604d is shown, and some components of the printing unit 201 of the printing module 200 discussed above are not present. Figure 19A and Figure 19BAs shown in the diagram. The movement of the four printhead supports 604a to 604d between the operating and maintenance positions also applies to print modules 200 with more than four supports and the print support 612 of print module 200. Figure 19A and Figure 19B (Not shown in the image).

[0054] refer to Figure 19A and Figure 19B Printhead supports 604a and 604d include a first terminal printhead support and a second terminal printhead support, and printhead supports 604b and 604c include an intermediate printhead support disposed between these terminal printhead supports. As described above, the first terminal printhead support 604a is fixed to the extendable arm 630 of the linear actuator 632. The second terminal printhead support is fixed to a fixing block or anchor 634 or the extendable arm 630a of another linear actuator 632a.

[0055] Position protrusions or sliding limiters 640a to 640c extend from the second terminal printhead holder 604d and the intermediate printhead holders 604b and 604c, respectively. Each protrusion 640a to 640c extends from the rear plates 618b and 618d of the printhead holders 604b to 604d, respectively, along the first sidewalls 642b to 642d. Further, each protrusion 640a to 640c extends toward the second sidewalls 644a to 644c of the adjacent printhead holders 604a to 604c. As described in detail below, when the printhead holders 604 are in the operating position, the length of the protrusions 640 extending into the space between the printhead holders 604 determines the spacing between the printheads 500. In one embodiment, the protrusion 640 is a micron screw screwed into the sidewall 642, a wedge disposed on the sidewall 642, or other type of spacer disposed on the sidewall 642 that is obvious to those skilled in the art. It will be apparent to those skilled in the art that other types of protrusions may be used.

[0056] When the plurality of printhead holders 604 are in the operating (i.e., printing) position (in Figure 19A When shown in the diagram, the extendable arm 630 of the linear actuator 632 (and, if used, the extendable arm 630a of the linear actuator 632a) is in the extended position. Additionally, adjacent printhead supports 604 are positioned such that the sidewall 646 of each protrusion 640 extending from the first sidewall 642 of the rear plate 618 of each first printhead support 604 abuts the second sidewall 644 of the second printhead support 604 adjacent to the first printhead support 604. As a result, the space between the sidewalls 642, 644 of adjacent supports is substantially the same length as the protrusion 640 extending from the first sidewall 642 into this space.

[0057] Furthermore, the first pillars 648a to 648c are respectively positioned close to the second sidewalls 644a to 644c of the rear plates 618a to 618c of the printhead supports 202a to 604c. The second pillars 650a to 650c are respectively positioned close to the first sidewalls 642b to 642d of the rear plates 618b to 618d of the printhead supports 604b to 604d. Therefore, the first terminal printhead support 604a has a first pillar 648a, the second terminal printhead support 604d has a second pillar 650c, and each intermediate printhead support 604b, 604c has both a first pillar 648 and a second pillar 650. Each first pillar 648 provided on the first printhead support 604 and each second pillar 650 provided on the second printhead support 604 adjacent to the first printhead support are substantially collinear with respect to each other. Furthermore, the connecting rod or ring 652 connects the first post 648 on the first printhead support 604 and the second post 650 on the second printhead support 604 adjacent to the first printhead support.

[0058] When the printhead holder 604 is in the maintenance position (in Figure 19B As shown in the diagram, the extendable arm 630 of the linear actuator 632 is in the retracted position, and the adjacent printhead holder 604 is positioned such that the first distal inner end 654 and the second distal inner end 656 of each link 652 contact the first post 648 and the second post 650 of the adjacent printhead holder 604 surrounded by such links 652. Therefore, the space between the sidewalls 642, 644 of the rear plate 618 of the adjacent printhead holder 604 is substantially the same as the length of the opening of the link 652 (i.e., the distance between the first distal inner end 654 and the second distal inner end 656 of such link 652).

[0059] As described above, the global controller 110 operates the printhead transport device 114 in response to operator commands to move the printhead holder 604 from the operating position to the maintenance position and from the maintenance position to the operating position. In one embodiment, the printhead transport device 114 includes a printhead transport controller 658 that receives operator commands received by the global controller 110 and, in response, operates the linear actuator 632 (and the linear brake 632a, if appropriate), as described below.

[0060] Figure 20 This illustrates the printhead transport controller 658 of the global controller 110. Figure 19A , Figure 19B The flowchart for the processing is 700. See also: Figure 9At block 702, the printhead transport controller 658 waits until it receives a command from the operator via the global controller 110. At block 704, the printhead transport controller 658 determines whether the command is an instruction to move the printhead holder 604 into the operating position, and if so, the printhead transport controller 658 proceeds to block 706; otherwise, the printhead transport controller 658 proceeds to block 708.

[0061] At block 706, printhead transport controller 658 actuates linear actuator 632 to extend arm 630. In those embodiments where terminal printhead 604x is coupled to the extendable arm 630a of linear actuator 632a, printhead transport controller 658 also actuates linear actuator 632a. This forces the first printhead support 604a (and 604a) coupled to arm 630 (and arm 630a) and intermediate printhead supports 604b, 604c closer together. The printhead transport controller 658 actuates the linear actuator 632 (and the linear actuator 632a) to extend the arm 630 (and the arm 630a) a predetermined distance, which is necessary for all the sidewalls 646 of the protrusions 640 provided on the first sidewall 642 of the rear plate 618d of the second terminal printhead holder 604d and the intermediate printhead holders 604b, 604c to contact and abut against the first sidewall 642 of the intermediate printhead holders 604b, 604c and the first terminal printhead holder 604a, respectively.

[0062] After block 706, printhead transport controller 658 continues to block 702, awaiting another command.

[0063] At block 708, printhead transport controller 658 determines whether the command received at block 702 is an instruction to move to a maintenance position. If so, printhead transport controller 658 proceeds to block 710; otherwise, printhead transport controller 658 proceeds to block 712.

[0064] At block 710, the printhead transport controller 658 operates the linear actuator 632 to retract the arm 630. In those embodiments where the terminal printhead support 604x is coupled to the arm 630a of the linear actuator 632a, the printhead transport controller 658 also operates the linear actuator 632a to retract the arm 630a. This pulls the first terminal printhead support 604a and the intermediate printhead supports 604b, 604c toward the linear actuator 632 (linear actuator 632a, if appropriate). The printhead transport controller 658 operates the linear actuators 632 (and 632a) to cause the arm 630 (and 630a) to retract by a predetermined amount, which is necessary for the first distal inner end 654 and the second distal inner end 656 of all links 652 to contact the first post 648 and the second post 650 surrounded by such links. In embodiments where the second terminal printhead holder 604d is anchored to block 634 and cannot move, the amount of movement of the first terminal printhead holder 604d and the intermediate printhead holder is limited by the distance between the first distal inner end 654 and the second distal inner end 656 of link 652. Similarly, in embodiments where the second terminal printhead holder 604x is coupled to linear actuator 632a, the movement of the first terminal holder 604a, the second terminal holder 604x, and the intermediate printhead holder therebetween is limited by the first distal inner end 654 and the second distal inner end 656 of link 652. Thereafter, printhead transport controller 658 proceeds to block 702 to await another command.

[0065] At block 712, the printhead transport controller 658 determines whether the command received at block 702 is an instruction to initiate the shutdown of the print module 200. If so, at block 714, the printhead transport controller 658 operates the linear actuator 632 to move the print module 200 to a maintenance position (or another predetermined position between the operating position and the maintenance position) and exits. Otherwise, the printhead transport controller 658 returns to block 702 to await another command.

[0066] In some embodiments, at blocks 706 and 710, the printhead transport controller 658 checks whether arms 630 (and arm 630a) are already in an extended or retracted state, and if so, does not further extend or retract the arms(s). Similarly, at block 714, the printhead transport controller 658 checks the position of arms 630 (and arm 630a) to determine whether to retract, extend, or maintain their position, thereby moving the printing unit 600 to a maintenance position or other predetermined other position.

[0067] Although the foregoing describes the movement of the printhead support 604 of the printing unit 602 between the operating position and the maintenance position, it will be apparent to those skilled in the art that the printhead support 612 of the printing unit 602 can move between the operating position and the maintenance position in substantially the same manner. Furthermore, although Figure 19A and Figure 19B Two intermediate printhead supports 604 are shown between two terminal printhead supports 604, but it will be apparent to those skilled in the art that the printing unit 602 may include more or fewer intermediate printhead supports 604 disposed between the two terminal printhead supports 604, and such terminal printhead supports and more or fewer printhead supports may be movable between an operating position and a maintenance position, as described above.

[0068] Figure 21 and Figure 22 Another embodiment 800 of the printing module 200 is shown, which is functionally similar to the embodiment 600 described above. Like embodiment 600, embodiment 800 includes substantially identical first printing units 802a and second printing units 802b disposed on opposite sides of a central rod 608. Each printing unit 802 includes terminal printhead supports 804a and 804h, intermediate printhead supports 804b to 804g disposed between the terminal printhead supports 804a and 804h, and a printhead 500 disposed in each printhead support 804.

[0069] The first transport block 806 and the second transport block 808 are respectively fastened to the sidewalls 810 and 812 of the terminal printhead holders 804a and 804h. A stop block 814 is also fastened to the sidewall 810. Specifically, the stop block 814 has a base portion 816, a first side portion 818 extending downward from the base portion 816, and a second side portion 820. The base portion 816 and the side portions 818 and 820 combine to form an inverted U-shape. Additionally, an extension portion 822 extends from the second side portion 820 and is fastened to the sidewall 810. In some embodiments, the extension portion 822 is substantially parallel to the base portion 816.

[0070] The printing unit 802 further includes a first linear actuator (such as a low-friction cylinder) 824 and a second linear actuator (such as a low-friction cylinder) 826 having extension arms 825 and 827, respectively, the extension arms 825 and 827 being connected to a first transport block 806 and a second transport block 808, respectively. In some embodiments, the extension arms 825 and 827 include threaded portions that are screwed into corresponding threaded portions of the transport blocks 806 and 808, respectively.

[0071] Also refer to Figure 22Each intermediate printhead holder 804b-804g includes first spacer blocks 828a-828f. Additionally, the terminal printhead holder 804h, located away from the stop block 814 and fixed to the second transport block 808, also includes a first spacer block 828g. The terminal printhead holder 804a does not include the first spacer block 828g. Instead, an extension 822 of the stop block 814 is disposed in the space originally occupied by the first spacer block 828, and the extension 822 is fixed to the terminal printhead holder 804a.

[0072] With the printhead holder 604 and protrusion 640 described above (see above) Figure 15-19B Similarly, each printhead holder 804 includes a protrusion 830 that is fixed to and extends outward from the sidewall 832 of the second spacer block 836, which is fixed to the printhead holder 804.

[0073] Additionally, the second spacer block 836 includes a cavity 840 ( Figure 21B An extension element 842 of the first spacer block 828 is disposed in the cavity. The cavity 840 is defined and delimited on one side by a sidewall 844.

[0074] Printhead transport controller 658 (see Figure 19A , 19B and Figure 20 The first linear actuator 824 and the second linear actuator 826 are operated to move the printhead support 804 of the printing unit 802 between the printing position and the maintenance position.

[0075] Specifically, in order to move the printhead holder 804 from the printing position to the maintenance position, the printhead transport controller 658 simultaneously operates the first linear actuator 824 and the second linear actuator 826. Figure 21 The extension arms 825 and 827 are retracted, thereby moving the first transport block 806 and the second transport block 808 (and thus the printhead holder 804) apart from each other until the first transport block 806 and the second transport block 808 contact the first mechanical stop 854 and the second mechanical stop 856, respectively. The first mechanical stop 854 is disposed between the transport block 806 and the first linear actuator 824, and the second mechanical stop 856 is disposed between the second transport block 808 and the second linear actuator 826.

[0076] Additionally, when the terminal printhead support 804a moves toward the first mechanical stop 854 due to the retraction of the extension arm 827, the sidewall 844 of the cavity 840 of the second spacer block 836a contacts the sidewall 846 of the extension element 842 of the first spacer block 828a (fixed to the intermediate printhead support 804b), thereby causing the intermediate printhead support 804b to also move toward the first mechanical stop 854.

[0077] Similarly, when the retraction of the extension arm 827 causes the terminal printhead holder 804h, fixed to the second transport block 808, to move toward the second mechanical stop 856, the sidewall 844 of the second spacer block 836g contacts the sidewall 846 of the extension element 842 of the first spacer block 828h of the terminal printhead holder 804h, thereby causing the printhead holder 804g to move toward the second mechanical stop 856. In this way, the movement of the terminal printhead holders 804a and 804h toward the first mechanical stop 854 and the second mechanical stop 856, respectively, causes the intermediate printhead holders 804b-804g to become spaced apart. After the printhead holders 804 have moved in this way, the printing unit 802 is in the maintenance position.

[0078] The distance that adjacent printhead supports 804 move is determined by the space between the sidewalls 844 and 846 of these adjacent printhead supports 804 when the printing unit 802 is in the printing position 802 (i.e., when the protrusion 830 of one printhead support 804 contacts the sidewall 834 of the printhead support 804 adjacent to that printhead support).

[0079] It will be apparent to those skilled in the art that, instead of using the interaction of the sidewall 844 of the second spacer block 836 and the sidewall 846 of the extension element 842 to set the amount of space between the printhead support 804 when the print unit 802 is in the maintenance position, the printhead support 804 can be adapted to use the linkage or ring 652 described above (see above) when the print unit 802 is in the maintenance position. Figure 19A , Figure 19B ( ) to connect and control the space between them.

[0080] When the printing unit 802 is in the maintenance position, the printhead holder 804 can be fully separated, allowing the use of vacuum devices, air jet devices, cleaning fluid flushing devices, etc., to remove any ink and other debris deposited on the sidewalls of the printhead holder 804 and / or the printhead 500. Furthermore, placing the printing unit 802 in the maintenance position facilitates the removal and / or replacement of the printhead holder 804 and / or the printhead 500, ensuring that the printhead holder 804 or printhead 500 does not come into contact and thus could not potentially damage adjacent printhead holders 804 or printheads 500.

[0081] Additionally, in some embodiments, the positions of the first mechanical stop 854 and the second mechanical stop 856, as well as the dimensions of the cavity 840 in the second spacer block 836 and the extension element 842 of the first spacer block 828, are selected such that when the printing unit 802 is in the maintenance position, the printhead supports 804 are separated, aligning each printhead support 804 and the printhead 500 disposed therein with a corresponding cleaning device (not shown), operable to clean the bottom surface 512 and / or sidewalls of the printhead supports 804 and / or the printheads 500. Such cleaning devices may include one or more wipers, one or more fluid jet devices, one or more vacuum devices, troughs and / or drains for capturing washed-out ink and / or jetted fluid, etc. In one embodiment, the spacing between the printhead supports 804 is approximately 0.065 inches when the printing unit 802 is in the maintenance position. That is, the distance between the sidewall 848 of the second spacer block 836 and the sidewall 850 of the adjacent second spacer block 836 near the sidewall 848 is approximately 0.065 inches.

[0082] In one embodiment, the first mechanical stop 854 includes a cylindrical head or buffer 858 fastened to one end of a screw 860, the screw 860 being passed through and fastened to a block 862 by a journal connection, and the block 862 being fastened to a central block 608 of the printing unit 802.

[0083] Similarly, the second mechanical stop 856 includes a cylindrical head or buffer 866 fastened to one end of a screw 868, which is passed through and fastened to a block 870 by a journal connection, and the block 870 is fastened to a center block 608. In one embodiment, the buffers 858, 866 have a large diameter (e.g., approximately 0.75 inches) that absorbs mechanical energy and thus prevents impact on the printhead 500 or printhead holder 804 when the first transport block 806 and the second transport block 808 contact the buffers 858, 866, respectively.

[0084] To move the print unit 602 from the maintenance position to the print position, the printhead transport controller 658 operates the first linear actuator 824 and the second linear actuator 826 to extend their extension arms 825, 827, thereby pushing the first transport block 806 and the second transport block 808 toward each other and thus moving the printhead support 804 of the print unit 802 toward each other. The first transport block 806 and the second transport block 808 are pushed in this manner until the protrusions 830-830g of the printhead supports 804a-804g contact the sidewalls 834a-834g of the first spacer blocks 828a-828g of the printhead supports 804b-804h, respectively.

[0085] Furthermore, when the printhead holder 804 is in the printing position, the inner wall 872 of the first side portion 818 of the stop block 814 ( Figure 21 The inner wall 872 contacts the third mechanical stop 874. This contact between the inner wall 872 and the third mechanical stop 874 prevents the transport blocks 806, 808 (and thus the printhead holder 804) from moving further away from the first linear actuator 824. The printhead transport controller causes an additional movement of the printhead holders 804 toward each other, which is caused by operating the second linear actuator 826 to extend the extension arm 827 and thereby push the printhead holders 804 away from the second linear actuator 826 and toward the first linear actuator 824. Thus, when the printing unit 802 is in the printing position, the terminal printhead holder 804a is a predetermined distance from the third mechanical stop 874, and the remaining printhead holders 804b-804h are a predetermined distance from the terminal printhead holder 804a (and each other), as set by the amount by which the protrusion 830 extends from the sidewall 832 of each second spacer block 836.

[0086] In some embodiments, when the printing unit 802 moves to the printing position, the first linear actuator 824 and the second linear actuator 826 operate to apply different amounts of pressure to the transport blocks 806, 808. In one embodiment, the first linear actuator 824 operates to apply a greater pressure to the transport block 806 than the pressure applied to the transport block 808 by the linear actuator 826. Operating the first linear actuator 824 and the second linear actuator 826 in this manner ensures that the inner wall 872 of the first side portion 818 of the stop block 814 is pushed against the third mechanical stop 874, and thus the print head 500a, fixed to the stop block 814, will be in a predetermined position relative to the third mechanical stop 874.

[0087] In some embodiments, the printhead transport controller 658 operates the first linear actuator 824 and the second linear actuator 826 to continuously apply pressure to the transport blocks 806, 808 when the print unit 802 is in the print position, so that the printhead holder 804 does not accidentally separate.

[0088] Additionally, the printhead transport controller 658 can adjust the pressure applied to the transport blocks 806, 808 by the first linear actuator 824 and the second linear actuator 826 when the print unit 802 is in the printing position, to force the printhead supports 804 closer or further apart, thereby allowing fine adjustment of the spacing between adjacent printhead supports 804. It will be apparent to those skilled in the art that forcing the printhead supports 804 closer together in this manner can temporarily compress the protrusion 830. This adjustment of the spacing can be made to adjust the seams between the printheads 500, for example, to compensate for wear on the mechanical components of the print unit 802, dirt or lubrication loss on the linear support tracks 624, 628, etc.

[0089] The printhead holder 804 includes an alignment mechanism to align the printhead 500 relative to the substrate and adjacent printheads 500. Figure 22-26 This alignment mechanism is shown.

[0090] refer to Figure 18 and Figure 22-26 Like the printhead holder 604, 612 ( Figure 18 Similarly, the printhead holder 804 includes a first plate 900 and a second plate 902, and the printhead 500 is removably fixed to the first plate 900. The first plate 900 and the second plate 902 are spaced apart and fixed to each other by a plurality of compression springs 904 and leaf springs 906.

[0091] As described in more detail below, protrusion 908 extends from the wall 910 of the second plate 902 toward the first plate 900. As described in more detail below, protrusion 908 is journal-connected through spacer 912, journal-connected through the second plate 902, and fixed to thumbwheel 914. Compression of spring 904 pushes the first plate 900 and the second plate 902 toward each other, thereby causing the wall 916 of the first plate 900 to remain in contact with protrusion 908.

[0092] Rotating the thumbwheel 914 in the first direction causes the protrusion 908 to extend away from the wall 910, thereby causing the first plate 900 (and printhead 500) near the protrusion 908 to move away from the second plate 902. Since the plurality of leaf springs 906 also connect the first plate 900 and the second plate 902, this movement causes the leaf springs 906 to flex and the first plate 900 (and therefore the printhead 500) to rotate about a pivot point 918 beyond the leaf springs 906 in the first direction A.

[0093] Rotating the thumbwheel 914 in a second direction opposite to the first direction causes the protrusion 908 to retract toward the wall 910. This retraction, combined with the compression of the spring 904, causes the first plate 900 near the protrusion 908 to move toward the second plate 902, and due to the leaf spring 906, the first plate 900 (and therefore the printhead 500) rotates about the pivot point 918 in a second direction opposite to the first direction A. Thus, the operator can use the thumbwheel 914 to make the printhead 500 of the printing unit 802 relative to each other and the center block 608 (… Figure 18 )alignment.

[0094] Figure 25 and Figure 25A Details of protrusion 908 are shown. See also: Figure 25 and Figure 25A The protrusion 908 includes an end portion 920 located at one end of a fine-threaded screw 922, which is screwed into a bushing or collar 924. The bushing 924 (and therefore the screw 922) is journal-connected through the second plate 902, and a portion of the threaded screw 920 extending beyond the bushing 924 is inserted into a hole in the thumb wheel 914, and this portion is secured to the thumb wheel 914 by a set screw 926. The bushing is secured to the plate 902 by a set screw 928.

[0095] By adjusting the amount by which the protrusion 830 extends from the sidewall 832 of the second spacer block 836 fixed to the second plate 902, a predetermined distance between adjacent printheads 500 is modified. This predetermined distance is necessary for accurate seams in the resulting prints. The protrusion 830 is journal-connected through the second spacer block 836 and fixed to the thumb wheel 926. The protrusion 830 is substantially the same as the protrusion 908 and is fixed to the thumb wheel 926 in a similar manner to how the protrusion 908 is fixed to the thumb wheel 914, as described above. Figure 23 As described. Rotating the thumb wheel 926 in a first direction causes the protrusion 830 to extend away from the sidewall 832 of the second spacer block 836 and the sidewall 834 of the first spacer block 828 toward the adjacent printhead support 804, and rotating the thumb wheel 926 in a second direction opposite to the first direction causes the protrusion 830 to retract toward the sidewall 832.

[0096] In one embodiment, the fine-threaded screw 922, including protrusions 830 and 908, comprises approximately 254 threads per inch to allow for fine adjustment of the spacing and rotation between printheads 500, such that the prints produced by adjacent printheads 500 are accurately seamed.

[0097] It will be apparent to those skilled in the art that the alignment features discussed in conjunction with printhead holder 804 can be incorporated into printhead holder 604.

[0098] refer to Figure 18 and Figure 26 Each printhead holder 804 includes a first linear support block 622 and a second linear support block 626. These linear support blocks facilitate fixing the printhead holder 804 to the first linear support track 624 and the second linear support track 628 of the center block 608 of the printing unit, respectively, as described above. Figure 15-1 As described in 9.

[0099] With printing unit 201 ( Figure 12 Similarly, printing units 602, 610 of embodiment 600 and printing unit 802 of embodiment 800 of printing module 200 are configured for use with one or more printheads 500 having a first side edge 516 and a second side edge 518 that are not parallel to the processing direction 538. Furthermore, these printing units 602, 610, and 802 can also be used with one or more printheads 500 having a first side edge 516 and / or a second side edge 518 parallel to the processing direction 538. For example, in addition to the Fuji Samb series printheads discussed above in conjunction with printing unit 201, printing units 602, 610, and 802 can also be used with, for example, printheads sold by Kyocera Corporation of Kyoto, Japan (part number KJ4B-YH06WST-SL1V).

[0100] Figure 27 With regard to the above discussion Figure 21 Essentially the same, and shows a rod 950 that can be secured to the frame 952 of the printing unit 802. The bottom edge 954 extends toward the substrate beyond the bottom surface 512 of the print head 500 by approximately 0.010 to 0.020 inches.

[0101] The rod 950 prevents contact between the substrate being printed, defects in the substrate and / or any debris that may be present on such substrate and the bottom surface 512 of the print head 500.

[0102] This written description uses examples to disclose the invention (including the best mode) and also enables those skilled in the art to practice the invention, including making and using any apparatus or system and performing any of the combined methods. The patentable scope of the invention is defined by the claims and may include other examples that would occur to those skilled in the art. Such other examples are intended to fall within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements that are not substantially different from the literal language of the claims.

[0103] Industrial applicability All references cited in this document (including publications, patent applications and patents) are hereby incorporated by reference to the extent that each reference is individually and specifically indicated as incorporated by reference and as set forth in its entirety in this document.

[0104] In the context of describing this invention (especially in the context of the following claims), the terms “a,” “an,” and “the,” and similar references, will be interpreted as covering both the singular and plural, unless otherwise indicated herein or obviously contradicted by the context. Unless otherwise indicated herein, descriptions of value ranges herein are intended merely as a shorthand method for individually referring to each individual value falling within that range, and each individual value is incorporated into the specification as if it were described separately herein. Unless otherwise indicated herein or obviously contradicted by the context, all methods described herein can be performed in any suitable order. The use of any and all examples or exemplary language (e.g., “such as”) provided herein is intended merely to better illustrate this disclosure and does not constitute a limitation on the scope of this disclosure, unless otherwise stated. No language in the specification should be construed as indicating that any unclaimed element is essential to the practice of this disclosure.

[0105] In view of the foregoing description, numerous modifications to this disclosure will be apparent to those skilled in the art. It should be understood that the illustrated embodiments are merely exemplary and should not be construed as limiting the scope of this disclosure.

Claims

1. A system for printing on a polymer film web, the system comprising: At least one track; Linear actuator; First and second adjacent printhead supports are slidably disposed on the at least one track; as well as A protrusion that extends from the first printhead support toward the second printhead support; The operation of the linear actuator causes the printhead holder to move between a first position and a second position. In the first position, the protrusion contacts the second printhead holder, and in the second position, the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. The link slidably interconnects the first printhead holder and the second printhead holder, wherein the link has an elongated opening with a length dimension, and the predetermined distance is determined by the length dimension of the link opening.

2. A system for printing on a polymer film web, the system comprising: At least one track; Linear actuator; First and second adjacent printhead supports are slidably disposed on the at least one track; as well as A protrusion that extends from the first printhead support toward the second printhead support; The operation of the linear actuator causes the printhead holder to move between a first position and a second position. In the first position, the protrusion contacts the second printhead holder, and in the second position, the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. The first printhead holder includes a cavity defined by a first sidewall, the second printhead holder includes an extension element disposed in the cavity, and the predetermined distance is determined by the distance between the first sidewall and the second sidewall of the extension element when the protrusion contacts the second printhead holder.

3. The system according to claim 2, wherein, The linear actuator operates to cause the first printhead holder to move toward the linear actuator, and the movement of the first sidewall toward the linear actuator causes the second sidewall to move toward the linear actuator.

4. The system of claim 1, further comprising an adjustment mechanism to adjust the space between the first printhead support and the second printhead support when the protrusion contacts the second printhead support.

5. A system for printing on a polymer film web, the system comprising: At least one track; Linear actuator; First and second adjacent printhead supports are slidably disposed on the at least one track; as well as A protrusion that extends from the first printhead support toward the second printhead support; The operation of the linear actuator causes the printhead holder to move between a first position and a second position. In the first position, the protrusion contacts the second printhead holder, and in the second position, the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. The linear actuator includes a first linear actuator, and the system further includes a third printhead holder disposed on the at least one track and a second linear actuator. The first linear actuator and the second linear actuator are operated to move the first printhead and the second printhead from the first position to the second position. The first linear actuator causes the first printhead holder to move toward the first linear actuator, and the second linear actuator causes the third printhead to move toward the second linear actuator.

6. The system according to claim 5, wherein, The protrusion includes a first protrusion and further includes operating the first linear actuator and the second linear actuator to move the first printhead to the third printhead from the second position to a third position, in which the first protrusion and the second protrusion extending from the first printhead and the second printhead respectively contact the second printhead and the third printhead.

7. The system according to claim 6, wherein, The first and second linear actuators operate to apply different amounts of force when moving the printhead holder from the second position to the third position.

8. A system for printing on a polymer film web, the system comprising: At least one track; Linear actuator; First and second adjacent printhead supports are slidably disposed on the at least one track; as well as A protrusion that extends from the first printhead support toward the second printhead support; The operation of the linear actuator causes the printhead holder to move between a first position and a second position. In the first position, the protrusion contacts the second printhead holder, and in the second position, the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. The first printhead support includes a first plate and a second plate connected by one or both of a compression spring and a leaf spring, and the system further includes an adjustment mechanism for determining the space between the first plate and the second plate.

9. The system according to claim 8, wherein, The adjustment mechanism rotates the first plate relative to the second plate.

10. The system of claim 8, further comprising a printhead disposed on the first plate.

11. A method for printing on a polymer film web, the method comprising: The first and second adjacent printhead holders are slidably mounted on at least one track; as well as A linear actuator is operated to move the first printhead holder and the second printhead holder between a first position and a second position, wherein in the first position a protrusion extending from the first printhead holder contacts the second printhead holder, and in the second position the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. The first printhead holder and the second printhead holder are slidably interconnected by a connecting rod, wherein the connecting rod has an elongated opening with a length dimension, and the predetermined distance is determined by the length dimension of the opening of the connecting rod.

12. A method for printing on a polymer film web, the method comprising: The first and second adjacent printhead holders are slidably mounted on at least one track; as well as A linear actuator is operated to move the first printhead holder and the second printhead holder between a first position and a second position, wherein in the first position a protrusion extending from the first printhead holder contacts the second printhead holder, and in the second position the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. and It further includes: disposing an extension element of the second printhead holder into a cavity of the first printhead holder, wherein the cavity is defined by a first sidewall and the extension element has a second sidewall, and the predetermined distance is determined by the distance between the first sidewall and the second sidewall when the protrusion contacts the second printhead holder.

13. The method of claim 12, further comprising: The linear actuator is operated to cause the first printhead holder to move toward the linear actuator, and the movement of the first sidewall toward the linear actuator causes the second sidewall to move toward the linear actuator.

14. A method for printing on a polymer film web, the method comprising: The first and second adjacent printhead holders are slidably mounted on at least one track; as well as A linear actuator is operated to move the first printhead holder and the second printhead holder between a first position and a second position, wherein in the first position a protrusion extending from the first printhead holder contacts the second printhead holder, and in the second position the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. and The linear actuator includes a first linear actuator, and the method further includes: setting a third printhead holder, and operating the first linear actuator and the second linear actuator to move the first printhead and the second printhead from the first position to the second position, wherein the first linear actuator causes the first printhead holder to move toward the first linear actuator, and the second linear actuator causes the third printhead to move toward the second linear actuator.

15. The method according to claim 14, wherein, The protrusion includes a first protrusion, and the method further includes: operating the first linear actuator and the second linear actuator to move the first printhead to the third printhead from the second position to a third position, in which the first protrusion and the second protrusion extending from the first printhead and the second printhead respectively contact the second printhead and the third printhead.

16. The method according to claim 15, wherein, Operating the first linear actuator and the second linear actuator includes operating the first linear actuator and the second linear actuator to apply different amounts of force when moving the printhead holder from the second position to the third position.

17. A method for printing on a polymer film web, the method comprising: The first and second adjacent printhead holders are slidably mounted on at least one track; as well as A linear actuator is operated to move the first printhead holder and the second printhead holder between a first position and a second position, wherein in the first position a protrusion extending from the first printhead holder contacts the second printhead holder, and in the second position the protrusion does not contact the second printhead holder, and the first printhead holder and the second printhead holder are separated by a predetermined distance. and The first printhead support includes a first plate and a second plate. The method further includes: using one or both of a compression spring and a leaf spring to connect the first plate and the second plate. The method further includes: operating an adjustment mechanism to adjust the space between the first plate and the second plate.

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