Printer, printer operation method, and substrate operation mechanism

Abstract

To propose a printing method and printing system for operating a substrate turned in a different direction, taking into account the case where a printing material is discharged onto the substrate while the substrate is turned in one direction or the other direction different therefrom.SOLUTION: A printer comprises a substrate support, a print head assembly, a first actuator, a second actuator, and a control unit. The print head assembly deposits a material onto a substrate supported on the substrate support. The first actuator arranged along a side part of the substrate support is connected to a first straight line track directed in a first direction. The second actuator arranged along an end part of the substrate support is connected to a second straight line track directed in a second direction perpendicular to the first direction. The first actuator and the second actuator are arranged so as to simultaneously engage with the substrate. The control unit rotates the substrate by moving the first actuator together with the second actuator.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Patent Application No. 62 / 969,218, filed February 3, 2020, the disclosure of which is incorporated herein by reference in its entirety.

[0002] FIELD OF THE INVENTION Embodiments of the present application relate generally to inkjet printing systems. In particular, methods, systems, and / or apparatus for manipulating a substrate in an inkjet printing system are described. [Background technology]

[0003] Inkjet printing is commonly used in office and home printers, as well as industrial-scale printers used for display manufacturing, high-volume document printing, material deposition on products such as printed circuit boards (PCBs), and biological product manufacturing such as tissue. Commercial, industrial, and / or consumer inkjet printers use a dispenser to apply a printing material to a substrate. The dispenser dispenses a controlled amount of printing material onto the substrate at a controlled time and speed. Once the printing material reaches a target location on the substrate, it forms a printed feature of a desired size and shape. In some cases, the printing material is dispensed onto the substrate while the substrate is oriented in one direction, and in other cases, the printing material is dispensed onto the substrate while the substrate is oriented in a different direction. In light of this, a printing method and / or printing system is proposed that operates on substrates oriented in different directions. Summary of the Invention

[0004] In at least one embodiment, the printer includes a substrate support, a holder assembly, a print head assembly, a first actuator, a second actuator, and a controller. The holder assembly is movable in a first direction relative to the substrate support and configured to hold and translate the substrate in the first direction while the substrate is supported on the substrate support. The print head assembly is movable in a second direction intersecting the first direction relative to the substrate support and configured to deposit printing material on the substrate. The first actuator is movable in the first direction relative to the substrate support and configured to hold a first portion of the substrate. The second actuator is movable in the second direction relative to the substrate support and configured to hold a second portion of the substrate. The controller is coupled to the first and second actuators and configured to control the first and second actuators to move simultaneously in the first and second directions, respectively, to rotate the substrate while the substrate is supported on the substrate support from a first orientation associated with a first format to a second orientation associated with a second format. The first format is one of a portrait format having a length in a first direction and a width in a second direction, and a landscape format having a width in the first direction and a length in the second direction. The second format is the other of the portrait format and the landscape format.

[0005] In at least one embodiment, a method for manipulating a substrate in a printer includes supporting the substrate on a substrate support. The substrate is rotated by holding a first portion of the substrate with a first end effector of a first actuator and holding a second portion of the substrate with a second end effector of a second actuator, and simultaneously moving the first actuator in a first direction and the second actuator in a second direction intersecting the first direction to rotate the substrate from a first orientation associated with the first format to a second orientation associated with the second format. The first format is one of a portrait format having a length in the first direction and a width in the second direction, and a landscape format having a width in the first direction and a length in the second direction. The second format is the other of the portrait format and the landscape format. The first end effector is rotatable about a first axis of rotation. The second end effector is rotatable about a second axis of rotation different from the first axis of rotation. During rotation of the substrate, the first end effector and the second end effector rotate together with the substrate about the first axis of rotation and the second axis of rotation, respectively.

[0006] In at least one embodiment, a substrate handling mechanism for a printer includes a first actuator, a second actuator, and a controller. The first actuator is movable in a first direction relative to the substrate support. The second actuator is movable in a second direction intersecting the first direction relative to the substrate support. The controller is coupled to the first and second actuators and configured to control the first and second actuators to move simultaneously in the first and second directions, respectively. At least one of the first and second actuators includes a carriage, an arm, and an end effector. The carriage is coupled to a rail extending along the substrate support in the corresponding first or second direction and is movable along the rail. The arm extends from the carriage toward the substrate support. The end effector is pivotally coupled to an end of the arm and is free to rotate during simultaneous movement of the first and second actuators. [Brief explanation of the drawings]

[0007] Aspects of the present disclosure will be best understood from the following detailed description when read in conjunction with the accompanying drawings, in which: In accordance with standard industry practice, the various features are not drawn to scale, and in fact the dimensions of the various features may be arbitrarily increased or decreased for illustrative purposes.

[0008] [Figure 1] FIG. 1 is a top isometric view of the printer.

[0009] [Figure 2] FIG. 1 is a schematic top view of a printer according to at least one embodiment.

[0010] [Figure 2A] FIG. 1 is a schematic top view of a portion of a printer according to at least one alternative embodiment.

[0011] [Figure 3A] 1A-1D are schematic top views of a portion of a printer at different stages of a substrate rotation operation in accordance with at least one embodiment. [Figure 3B] 1A-1D are schematic top views of a portion of a printer at different stages of a substrate rotation operation in accordance with at least one embodiment. [Figure 3C] 1A-1D are schematic top views of a portion of a printer at different stages of a substrate rotation operation in accordance with at least one embodiment. [Figure 3D] 1A-1D are schematic top views of a portion of a printer at different stages of a substrate rotation operation in accordance with at least one embodiment. [Figure 3E] 1A-1D are schematic top views of a portion of a printer at different stages of a substrate rotation operation in accordance with at least one embodiment.

[0012] [Figure 4A] 1 is a perspective view of parts of a printer according to at least one embodiment; [Figure 4B] 1 is a perspective view of parts of a printer according to at least one embodiment; [Figure 4C]1 is a schematic rear view of parts of a printer according to at least one embodiment. FIG.

[0013] [Figure 5A] 1 is an elevated side view of a portion of a printer in accordance with at least one embodiment, viewed from a first direction. [Figure 5B] 1 is an elevated side view of a portion of a printer in accordance with at least one embodiment, viewed from a second direction.

[0014] [Figure 6] 1 is a flowchart of a method for handling a substrate in a printer according to at least one embodiment.

[0015] [Figure 7] FIG. 2 is a block diagram of a controller according to at least one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0016] The following disclosure provides numerous embodiments or examples of various features of the present subject matter. Specific examples of components, values, operations, materials, arrangements, etc. are described below to facilitate understanding of the present disclosure. It should be understood that these specific examples are merely illustrative and are not intended to be limiting. Other components, values, operations, materials, arrangements, etc. are also contemplated. For example, although reference numerals and / or characters may be repeated in various examples throughout this disclosure, this repetition is for the purposes of brevity and clarity and does not dictate a relationship between the various embodiments and / or configurations described herein. Furthermore, for convenience of description, spatially relative terms such as "below," "under," "lower," "above," and "upper" may be used herein to describe the relationship of one element or feature shown in each figure to another element or feature. These spatially relative terms are intended to encompass various orientations of the device during use or operation in addition to the orientation depicted. Devices may be oriented in other orientations (e.g., rotated 90 degrees or otherwise), and the spatially relative descriptions used herein may be interpreted accordingly.

[0017] FIG. 1 is a top isometric view of a printer 100. The printer 100 includes a work platform 102, a printing assembly 104, and a holder assembly 106 for manipulating a substrate during printing. The printer 100 is mounted on a base 108. The base 108 is, in one example, a large component to minimize vibration transmission to the moving parts of the printer 100. In one example, the base 108 is made of granite. The work platform 102 is disposed on the base 108 and includes a support surface 110 and a device for making the support surface 110 substantially frictionless. In one example, the support surface 110 forms a gas cushion that suspends the substrate. The support surface 110 is characterized by a plurality of first holes 112 for ejecting gas, which provide an upward force that maintains the substrate at a desired height above the support surface 110. The support surface 110 may also be provided with a plurality of second holes that are controllably configured to suction gas from the gas cushion that suspends the substrate. This allows for precise local control of the substrate height.

[0018] The printing assembly 104 includes a jetting assembly 114 mounted on a print support 116. The print support 116 is mounted relative to the work table 102 to provide structural access for the jetting assembly 114 to precisely apply printing material to a substrate on the work table 102. The print support 116 includes a rail or beam 117 that traverses the work table 102, allowing the jetting assembly 114 to traverse the work table 102 and deposit printing material anywhere on the substrate between one side of the print support 116 and the other. In one example, the print support 116 is attached to a base 108 and extends from the base 108 to provide stable support for the jetting assembly 114. On either side of the work table 102, two stands 120 extend from the base 108 to rails 117. The rails 117 extend across the work table 102. In one example, the stands 120 and the rails 117 are both made of the same material as the base 108. In one example, the stand 120, rail 117, and base 108 are each separate pieces of granite that are bolted together.

[0019] The ejection assembly 114 includes at least one printhead assembly 119 and a print assembly controller 118. The print assembly controller 118 includes electronics and / or sensors that control the printhead assembly's 119 functional parameters, such as its position along the print substrate 116, timing, duration, type of printing material, and ejection profile. The printhead assembly 119 is movable along a rail 117 of the print substrate 116 by movement of a print carriage 122. The print carriage 122 is coupled to the print substrate 116 and translates the printhead assembly 119 along the rail 117 from one end of the rail 117 to the opposite end. In one example, the print carriage 122 is driven by a motor or servo motor. For clarity, power and signal lines are not shown.

[0020] A substrate (not shown in FIG. 1 ) is positioned below the printing assembly 104 by a holder assembly 106. The substrate may be a rigid substrate made of, for example, glass. The holder assembly 106 firmly contacts the substrate when placed on the printing assembly 104, and the holder assembly 106 moves or translates the substrate along the work table 102 to position the substrate relative to the printing assembly 104 so that the printing material is accurately dispensed onto the substrate. The holder assembly 106 is positioned on one side of the work table 102 and extends along the work table 102 in a first direction to translate the substrate in the first direction during printing. The first direction is indicated by an arrow 124 in FIG. 1 . The first direction 124 is referred to as the "Y direction." The print head assembly 119 moves in a second direction generally intersecting the first direction, guided by a rail 117. The rail 117 extends generally in the second direction indicated by an arrow 126 in FIG. 1 . The second direction 126 is referred to as the "X direction," and the rail 117 is referred to as the "X beam." A third direction, which generally intersects the first and second directions, is indicated by arrow 125 in Figure 1. Third direction 125 is referred to as the "Z direction." The X, Y, and Z directions are the axial directions of a coordinate system, indicated by arrows 124, 125, and 126, that serves as a frame of reference for printer 100. In one example, the origin of this coordinate system is a fixed point, such as based on base 108.

[0021] The holder assembly 106 is disposed on a holder assembly support 128. In one example, the holder assembly support 128 is a rail extending in a first direction along an edge 130 of the work table 102. In one example, the holder assembly support 128 is attached to the base 108, for example, with bolts, to stably support the holder assembly 106. In one example, the holder assembly support 128 is made of the same material as the base 108. The holder assembly support 128 may be referred to as a "Y-beam." The holder assembly 106 securely holds the substrate by, for example, vacuum or suction applied from multiple holes in the holder assembly 106 to multiple corresponding positions along the edge of the substrate. The vacuum or suction may be applied to the top side, bottom side, or both of the edge of the substrate. During operation, the holder assembly 106 moves along the holder assembly support 128 to position the securely held substrate at any desired position on the work table 102. Printing assembly 104, for example, by operation of printing assembly controller 118, positions printhead assembly 119 to allow precise access to locations on the substrate where printing material is to be dispensed.

[0022] In the example configuration described above, the holder assembly 106 moves the substrate in a first direction 124 while the dispensing assembly 114 moves in a second direction 126 to access any desired portion of the substrate. In other examples, the substrate is held stationary while the dispensing assembly moves in the first and second directions. In other examples, the dispensing assembly is held stationary while the substrate moves in the first and second directions 124 and 126. In yet other examples, both the holder assembly and the dispensing assembly move in the first and second directions 124 and 126. If the printable area of ​​the dispensing assembly differs from the desired area of ​​the substrate to be printed, the dispensing assembly and the substrate can be moved relative to each other to complete the printing job.

[0023] The system controller 129 receives signals from various sensors located throughout the printer 100 and sends signals to each component of the printer 100 to control printing. The system controller 129 is operably coupled to the print assembly controller 118 and the holder assembly controller 131, for example, via a network. The holder assembly controller 131 controls the operation of the holder assembly 106. One or more of the worktable 102, print assembly 104, holder assembly 106, and other auxiliary systems, such as an environmental control system or a material management system, have sensors operably coupled to the system controller 129 that send signals to the system controller 129 regarding the status of each component during a printing operation. The system controller 129 contains data and instructions for determining the control signals to send to each component of the printer 100 that it controls. In at least one embodiment, two or more of the system controller 129, print assembly controller 118, and holder assembly controller 131 are integrated into a single controller. In at least one embodiment, at least one of system control unit 129, print assembly control unit 118, and holder assembly control unit 131 is implemented as multiple control units distributed within printer 100 and connected to one another via a network. An example configuration of a control unit according to at least one embodiment is described with reference to FIG. 7. For simplicity, in the following description, "control unit" refers to one or more control units within printer 100 and / or one or more control units within a printing system using printer 100.

[0024] A particular substrate may have a particular orientation that is most advantageous for performing the designed printing operation on the substrate. For example, some substrates are advantageously processed in a "portrait" format, where the substrate is inserted into the printer parallel to its long dimension (i.e., length), while other substrates are advantageously processed in a "landscape" format, where the substrate is inserted into the printer parallel to its short dimension (i.e., width). Although the printer 100 can handle substrates and deposit printing material onto the substrate in both orientations, i.e., landscape and portrait formats, if other chambers or devices are used for post-deposition processing (also referred to herein as post-processing), such devices can only support the substrate in one orientation, necessitating multiple rotations of the substrate between the deposition and post-processing steps if the substrate needs to be reoriented between the deposition and post-processing steps. In complex printing systems including multiple printers, rotating the substrate between the deposition and post-processing steps may be undesirable if the substrate needs to be reoriented between the deposition and post-processing steps.

[0025] In this regard, a substrate handling mechanism for rotating a substrate in place within a printer is described herein. In one embodiment, the substrate handling mechanism includes two actuators that hold different portions of a substrate supported by a substrate support within the printer and are movable in two different, intersecting directions. Thus, a substrate can be rotated in place within the printer without the need for a separate chamber or device for rotating the substrate. Furthermore, a substrate rotated horizontally for printing material deposition can be rotated again to a vertical orientation for post-processing before being transported. This configuration saves time and increases productivity compared to other approaches that require separate rotation chambers before and / or after the printer to rotate the substrate to a desired orientation for printing material deposition and / or to rotate the substrate with deposited printing material to a desired orientation for post-processing. In this disclosure, "portrait orientation" and "landscape orientation" should be understood to refer to orientations corresponding to portrait and landscape formats, respectively. In this context, "portrait orientation" refers to a substrate orientation that allows the substrate to be processed in a portrait format, and "landscape orientation" refers to a substrate orientation that allows the substrate to be processed in a landscape format.

[0026] FIG. 2 is a schematic top view of a printer 200 according to at least one embodiment. The printer 200 includes various components similar to those of the printer 100. Some of these components are designated by the same reference numerals in FIG. 2, while others are omitted from FIG. 2 for clarity. Compared to the printer 100, the printer 200 includes not only the work table 102 but also a substrate support 260 including at least one extension, including a first extension 264 and / or a second extension 266. The printer 200 further includes a substrate handling mechanism 210 for rotating the substrate 220. The substrate handling mechanism 210 includes a first actuator 230, a second actuator 240, an auxiliary actuator 250, and a controller 270.

[0027] The first actuator 230 is shown schematically in Figure 2. The first actuator 230 is movable in a first direction (Y direction) relative to the substrate support 260 and is configured to hold a first portion 221 of the substrate 220. In the exemplary configuration of Figure 2, the first actuator 230 includes a carriage 232 coupled to and movable along a rail 234 (also referred to herein as a "linear track"), an arm 236 extending from the carriage 232 toward the substrate support 260, and an end effector 238 pivotally coupled to a distal end of the arm 236. The rail 234 is positioned outside the footprint of the substrate support 260 and extends in the Y direction along the substrate support 260 from a position adjacent to the rail 117 toward the outfeed end or outfeed side of the work table 102. Opposite the infeed end or infeed side (shown as "infeed" in the drawings) where the substrate 220 is fed to the work table 102 is the outfeed end or outfeed side (shown as "outfeed" in the drawings), which is the position where the substrate 220 arrives after the holder assembly 106 translates the substrate 220 from the infeed end in the Y direction and passes under the rail 117. The rail 234 is located on the opposite side of the holder assembly 106 from the substrate support 260 in the X direction. That is, the holder assembly 106 is disposed between the rail 234 and the substrate support 260 in the X direction. In one example, the carriage 232 is driven by a motor or servo motor (not shown) to move along the rail 234 in the Y direction. The arm 236 extends from the carriage 232 past the holder assembly 106 in the X direction, with the distal end of the arm 236 located above the substrate support 260. The end effector 238 extends in the Z direction downward from the distal end of the arm 236 toward the substrate support 260, as described below with respect to Figures 4A and 4B. The end effector 238 is configured to hold a corresponding first portion 221 of the substrate 220, e.g., by vacuum or suction force, and to rotate with the substrate 220 during rotation of the substrate 220, as described with respect to the exemplary embodiment of Figures 3A-3E. Figures 4A-4C show more detailed views of an exemplary embodiment of the first actuator 230.

[0028] The second actuator 240 is shown schematically in FIG. 2. The second actuator 240 is movable in a second direction (X direction) relative to the substrate support 260 and is configured to hold the second portion 222 of the substrate 220. In the exemplary configuration shown in FIG. 2, the second actuator 240 includes a carriage 242 coupled to and movable along a rail 244, an arm 246 extending from the carriage 242 toward the substrate support 260, and an end effector 248 pivotally coupled to the distal end of the arm 246. The rail 244 is positioned outside the installation area of ​​the substrate support 260, adjacent to the outfeed end or side of the work table 102, and extends in the X direction along the substrate support 260. In one example, the carriage 242 is driven by a motor or servo motor (not shown) to move along the rail 244 in the X direction. The arm 246 extends in the Y direction from the carriage 242 toward the substrate support 260, such that the distal end of the arm 246 is positionable above the substrate support 260. The end effector 248 extends downward in the Z direction from the distal end of the arm 246 toward the substrate support 260, as described below with respect to FIG. 4A. The end effector 248 is configured to hold a corresponding second portion 222 of the substrate 220, e.g., by vacuum or suction, and rotate with the substrate 220 during rotation, as described with respect to the exemplary embodiment of FIGS. 3A-3E. FIG. 4A shows a more detailed diagram of an exemplary embodiment of the second actuator 240. The above-described configurations of the first actuator 230 and / or second actuator 240 are merely examples, and other configurations are within the scope of various embodiments. For example, instead of being movable along rails, the first actuator 230 or second actuator 240 may be mounted on a rod that extends or retracts from a cylinder structure.

[0029] The auxiliary actuator 250 is shown schematically in FIG. 2. The auxiliary actuator 250 is configured to move the second actuator 240 in the Y direction. In the exemplary configuration shown in FIG. 2, the auxiliary actuator 250 includes a carriage 252 coupled to and movable along a pair of parallel rails 254A, 254B. The rails 254A, 254B extend in the Y direction from a position adjacent to the outfeed end of the work table 102, away from the substrate support 260. The rail 254A is closer to the rail 234 of the first actuator 230 than the rail 254B. The carriage 252 is coupled to an end 284A of the rail 244 of the second actuator 240, which is closer to the first actuator 230. The other end 284B of the rail 244, which is farther from the first actuator 230, is supported from below by the other rail 254B and is movable along the rail 254B. In one example, carriage 252 coupled to end 284A of rail 244 is driven by a motor or servo motor (not shown) to move along rail 254A and simultaneously move the other end 284B of rail 244 on the other rail 254B along rail 254B. As a result, second actuator 240 moves in the Y direction toward or away from substrate support 260 before and after rotating substrate 220, as described herein. In at least one embodiment, auxiliary actuator 250 is omitted.

[0030] FIG. 2A is a schematic top view of a portion of printer 200 including second actuator 240 and auxiliary actuator 250 according to at least one alternative embodiment. In the exemplary configuration of FIG. 2A , rails 254A, 254B, and 244 are integral. That is, unlike the configuration of FIG. 2 in which rail 244 is movable along rails 254A and 254B, rail 244 in FIG. 2A is fixed to rails 254A and 254B. Carriage 242 in FIG. 2A is also movable along rail 244 in the X direction, as in FIG. 2. However, movement in the Y direction is achieved in FIG. 2A by a rod 245 that telescopes from a cavity (not shown) within carriage 242, rather than by moving rail 244 along rails 254A and 254B as in FIG. 2. For example, rod 245 is in an extended state on the left side of FIG. 2A and in a retracted state on the right side of FIG. 2A. The extended state of rod 245 corresponds to the state described herein with respect to Figure 3A, i.e., the state in which end effector 248 attached to head 246A at the end of rod 245 begins to engage second portion 222 of substrate 220 before rotation of substrate 220. Rod 245 then retracts to a retracted state, moving substrate 220 to a position corresponding to Figure 3B. Rod 245 remains in the retracted state while carriage 242 moves along rail 244 during rotation of substrate 220, as described with respect to Figures 3B-3D. Then, after rotation of substrate 220, rod 245 again extends to an extended state, moving substrate 220 to a position corresponding to Figure 3E.

[0031] Returning to FIG. 2 , the substrate support 260 is configured to support the substrate 220 on the work table 102 while the substrate 220 translates along the Y direction. The substrate support 260 is further configured to support the substrate 220 with the main portion 262, the first extension portion 264, and the second extension portion 266 during rotation of the substrate 220. The main portion 262 is a portion of the work table 102 located at the outfeed end. The main portion 262 is rectangular and has a length and width sufficient to support the substrate 220 in both horizontal and vertical orientations. The first extension portion 264 is adjacent to the main portion 262 in the X direction. The first extension portion 264 has a size and / or shape sufficient to support the third portion 223 of the substrate 220 during rotation of the substrate 220, as described herein. To this end, the first extension portion 264 in the example configuration of FIG. 2 has curved and / or angled edges that correspond to the trajectory of the corresponding corner of the third portion 223 of the substrate 220. However, the above-described configuration of the first extension 264 is merely an example, and other configurations are within the scope of various embodiments. For example, the first extension 264 may have a rectangular shape that is elongated in the Y direction. The second extension 266 is adjacent to the main portion 262 in the Y direction. The second extension 266 is rectangular, elongated in the X direction, and has a length in the X direction that is approximately the same as the width of the main portion 262. The second extension 266 has dimensions that are sufficient to support the second portion 222 of the substrate 220 during rotation of the substrate 220, as described herein. As described further below, the second extension 266 is further configured to sufficiently support the third portion 223 of the substrate 220 before rotation and the first portion 221 of the substrate 220 after rotation.

[0032] Like the main portion 262 that is part of the worktable 102, the first extension 264 and the second extension 266 include a plurality of holes through which gas is ejected to provide an upward force that maintains the substrate 220 floating at a desired height, at least during rotation of the substrate 220. The first extension 264 and the second extension 266 may also be provided with a plurality of gas ejection holes that are controllably configured to suction gas from the gas cushion that floats the substrate 220. This allows for precise local control of the substrate height, at least during rotation of the substrate 220. In at least one embodiment, the gas cushion across the first extension 264 and / or the second extension 266 is generated and / or controlled by the same gas source and / or control that generates and / or controls the gas cushion across the main portion 262 of the worktable 102. This allows for uniform and substantially frictionless support of the substrate 220 during rotation of the substrate 220. Either or both of the first extension 264 and the second extension 266 may be formed separately from the work table 102. For example, the first extension 264 and the second extension 266 may each be formed separately and attached adjacent to the outfeed end of the work table 102 of an existing printer to enable in-place substrate rotation as described herein in the existing printer. Furthermore, either or both of the first extension 264 and the second extension 266 may be integral with the work table 102. For example, if the existing printer has a sufficiently long work table 102 whose outfeed end can function as both the main portion 262 and the second extension 266, simply attaching the first extension 264 adjacent to the outfeed end of the work table 102 of the existing printer may enable in-place substrate rotation as described herein in the existing printer. As another example, both the first extension 264 and the second extension 266 may be formed integral with the work table 102.

[0033] A controller 270 is coupled to the first actuator 230, the second actuator 240, and the auxiliary actuator 250 and controls the operation of the actuators, including, but not limited to, the individual and / or simultaneous movement of each actuator along their respective directions of movement and the engagement and / or disengagement of the end effectors 238, 248 of the first actuator 230 and the second actuator 240 with and / or from the respective portions 221, 222 of the substrate 220. The controller 270 may also be coupled to a gas source (not shown) and control a gas cushion across the substrate support 260. In at least one embodiment, the controller 270 is incorporated into one or more of the controllers described with respect to FIG. 1 . For example, the controller 270 may be incorporated into and implemented by the system controller 129. Substrate rotation by the substrate handling mechanism 210 within the printer 200 under control of the controller 270 is described with respect to FIGS. 3A through 3E .

[0034] 3A-3E are schematic top views of a portion of the printer 200 of FIG. 2 at various stages of a substrate rotation operation in accordance with at least one embodiment. For simplicity, various components of the printer 200 above the X-beam 117 (i.e., the infeed side) are omitted from FIGS. 3A-3E. FIG. 3A illustrates the transfer of the substrate 220 from the holder assembly 106 to the substrate handling mechanism 210 for the substrate rotation operation. FIG. 3B illustrates the substrate 220 at the beginning of the substrate rotation operation. FIG. 3C illustrates the substrate 220 during the substrate rotation operation. FIG. 3D illustrates the substrate 220 at the end of the substrate rotation operation. FIG. 3E illustrates the transfer of the rotated substrate 220 from the substrate handling mechanism 210 back to the holder assembly 106 after the substrate rotation operation. In FIGS. 3A-3E, the substrate rotation operation is performed using the second actuator 240 and auxiliary actuator 250 configuration described with reference to FIG. 2. Substrate rotation can also be achieved in a similar manner using the second actuator 240 and auxiliary actuator 250 configuration described with respect to Figure 2A.

[0035] In at least one embodiment, prior to the state of FIG. 3A , the substrate 220 is conveyed lengthwise to the infeed side (best shown in FIG. 2 ) of the work table 102, for example, by a robotic arm (not shown). The holder assembly 106 holds the substrate 220, for example, by vacuum or suction, at a plurality of first positions along a first edge 312 of the substrate 220. In FIG. 3A , the substrate is oriented such that the first edge 312 extends along the Y direction. The first edge 312 connects the first portion 221 of the substrate 220 with the second portion 222. The holder assembly 106, which holds the first edge 312 of the substrate 220, is then moved in the Y direction from the infeed side to the outfeed side, causing the substrate 220 to perform a first translation.

[0036] If the substrate 220 is transported through the printer 200 in a portrait orientation, for example, if the controller 270 determines that printing material is to be deposited only in a portrait orientation, rotation of the substrate 220 is not necessary. The print head assembly 119, moving in the X direction, deposits printing material onto the substrate 220 while the holder assembly 106 translates the substrate 220 in the Y direction. When the first translation of the substrate 220 in the Y direction is completed, the deposition of printing material is completed, and the holder assembly 106, still holding the first edge 312 of the substrate 220, moves back in the Y direction from the outfeed side to the infeed side. The substrate 220 with the deposited printing material is then picked up from the infeed side of the work table 102 for post-processing, for example, by a robot arm. Because the substrate was not rotated, the substrate 220 with the deposited printing material remains in a portrait orientation and is ready to be manipulated by subsequent post-processing chambers and / or post-processing devices, which are typically configured to handle substrates in a portrait orientation.

[0037] If it is determined, for example, by the controller 270, that at least a portion of the printing material is to be deposited in a horizontal orientation, the substrate 220 is rotated from a vertical orientation to a horizontal orientation. In an example in which the printing material is deposited only in a horizontal orientation, no printing material is deposited while the holder assembly 106 performs the first translation of the substrate 220 from the infeed side to the outfeed side. In another example in which the printing material is deposited in both a horizontal and vertical orientation, a portion of the printing material is deposited in a vertical orientation while the holder assembly 106 performs the first translation of the substrate 220 from the infeed side to the outfeed side. When the first translation of the substrate 220 is completed, the substrate 220 reaches the state shown in FIG. 3A .

[0038] 3A , the holder assembly 106 holds at least a portion or substantially the entire length of the first edge 312 and transports the substrate 220 to the end of the main portion 262. In this case, the edge 323 of the substrate 220 is transported by the holder assembly 106 to near the position of the edge 273, which is the boundary between the main portion 262 and the second extension portion 266. The first actuator 230 and the auxiliary actuator 250 are controlled to move in the Y direction so that the end effector 238 of the first actuator 230 is aligned with the corresponding first portion 221 of the substrate 220 and so that the end effector 248 of the second actuator 240 is aligned with the corresponding second portion 222 of the substrate 220. For example, the first rotational axis of the end effector 238 is aligned to coincide with a first corner of the substrate 220 in the first portion 221, as described in more detail with respect to FIG. 4B , e.g., by moving the first actuator 230. Similarly, the second rotational axis of the end effector 248 is aligned to coincide with a second corner of the substrate 220 in the second portion 222, e.g., by moving the second actuator 240. The coordinates of the substrate corners for alignment may be determined by settings instructed or input into the printer 200 by an operator. For example, if a substrate of predetermined dimensions is delivered to the printer 200 at a preset position on the infeed side of the work table 102, the coordinates of the substrate corners on the infeed side can be determined from the preset position to which the substrate is delivered and the predetermined dimensions of the substrate. The coordinates of the substrate corners on the outfeed side can be determined from the known coordinates of the substrate corners on the infeed side and a preset translation or distance of the holder assembly 106 that holds the substrate. Additionally or alternatively, the coordinates of the substrate corners on the outfeed side may be detected by a camera using image processing techniques. In yet another example, in addition to or instead of the coordinates of the substrate corners, the coordinates of features on the substrate that have a predefined positional relationship to the substrate corners are determined.Once end effector 238 is aligned with corresponding first portion 221 of substrate 220 and end effector 248 is aligned with corresponding second portion 222 of substrate 220, end effector 238 is controlled to engage corresponding first portion 221 of substrate 220 and end effector 248 is controlled to engage corresponding second portion 222 of substrate 220, as described in more detail with respect to FIG. 4B . Holder assembly 106 is controlled to release first edge 312 of substrate 220, for example, by ceasing application of vacuum or suction force to holder assembly 106, thereby effectively transferring substrate 220 from holder assembly 106 to substrate handling mechanism 210.

[0039] Next, as shown in Fig. 3B, the first actuator 230 and the auxiliary actuator 250 are controlled to move or translate the substrate 220 and the second actuator 240 in the Y direction toward the outfeed side from the state shown in Fig. 3A to the state shown in Fig. 3B. From this state, it is possible to proceed to the substrate rotation operation.

[0040] As shown in FIG. 3C , the controller 270 is configured to control the first actuator 230 and the second actuator 240 to simultaneously move in the Y and X directions, respectively, to rotate the substrate 220 while the substrate 220 is supported on the substrate support 260. During the rotation of the substrate 220, the first actuator 230 moves linearly in the Y direction toward the second actuator 240 or toward the infeed end, as shown by arrow 351 in FIG. 3C . Simultaneously, the second actuator 240 moves linearly in the X direction away from the first actuator 230 or away from the holder assembly 106, as shown by arrow 352 in FIG. 3C . During the simultaneous movement of the first actuator 230 and the second actuator 240, the end effectors 238 and 248 are free to rotate with the substrate 220 until the substrate 220 reaches the landscape orientation shown in FIG. 3D . In at least one embodiment, the substrate 220 is fully supported by the substrate support 260 throughout all stages of the substrate rotation motion. 3B , at the start of the substrate rotation operation, the first portion 221 and the fourth portion 224 of the substrate 220 are supported by the main portion 262, and the second portion 222 and the third portion 223 of the substrate 220 are supported by the second extension portion 266. During the substrate rotation operation illustrated in FIG. 3C , the first portion 221 of the substrate 220 is supported by the main portion 262 and then by the second extension portion 266, the second portion 222 of the substrate 220 is supported by the second extension portion 266, the third portion 223 of the substrate 220 is supported by the second extension portion 266, then by the first extension portion 264, and finally by the main portion 262, and the fourth portion 224 is supported by the main portion 262. 3D, when the substrate rotation operation is completed, the first portion 221 and the second portion 222 of the substrate 220 are supported by the second extension portion 266, and the third portion 223 and the fourth portion 224 of the substrate 220 are supported by the main portion 262. When the substrate 220 is in the horizontal orientation in FIG. 3D, the linear motions of the first actuator 230 and the second actuator 240 are controlled to stop.

[0041] As shown in FIG. 3D , the substrate 220 is reoriented to face sideways at the end of the substrate rotation operation. Specifically, the first edge 312 of the substrate 220 is reoriented in the X direction, rather than the Y direction as in FIG. 3B . The second edge 341 of the substrate 220, which connects the first and fourth portions 221 and 224 of the substrate 220 and previously faced the X direction in FIG. 3B , is reoriented in the Y direction in FIG. 3D . The second edge 341 is aligned with at least some of the vacuum or suction holes of the holder assembly 106 and is capable of being held by the holder assembly 106. By aligning the rotation axes of the end effectors 238 and 248 with the corresponding corners of the substrate 220 as described above, the second edge 341 of the substrate 220 is aligned with the holder assembly 106 along the Y direction without the need for realignment after rotation.

[0042] 3E, at the end of the substrate rotation operation of FIG. 3D, the first actuator 230 and the auxiliary actuator 250 are controlled to move or translate the substrate 220 and the second actuator 240 toward the infeed side in the Y direction to a position shown in FIG. 3E where at least a portion of, or substantially the entire length of, the second edge 341 can be held by the holder assembly 106. The holder assembly 106 is then controlled to apply a vacuum or suction force to hold a portion, the entire length, or substantially the entire length of the second edge 341 of the substrate 220. Thereafter, the end effectors 238 and 248 are controlled to disengage from the corresponding first and second portions 221 and 222 of the substrate 220, thereby effectively transferring the rotated substrate 220 from the substrate handling mechanism 210 back to the holder assembly 106.

[0043] Next, in a second translation of the substrate 220, the holder assembly 106, which at least partially holds the second edge 341, translates the currently horizontally oriented substrate 220 in the Y direction back to the infeed side. In a third translation of the substrate 220, the holder assembly 106 again translates the currently horizontally oriented substrate 220 in the Y direction back to the outfeed side. During the third translation of the substrate 220, the printing material is deposited on the substrate 220 in the desired horizontal orientation. At the end of the third translation, the substrate 220 on which the printing material has been deposited is rotated by a substrate flipping operation from the horizontal orientation of FIG. 3D to the intermediate states illustrated in FIG. 3C and then back to the vertical orientation of FIG. 3B. The vertically oriented substrate 220 on which the printing material has been deposited is then returned in the Y direction by the holder assembly 106 in a fourth translation, after which it is picked up by, for example, a robot arm for post-processing. Although the substrate 220 has printing material deposited thereon in a desired landscape orientation, it exits the printer 200 in a portrait orientation, ready to be manipulated by subsequent post-processing chambers and / or devices that are typically configured to handle substrates in a portrait orientation. With an in-place rotational printer, a separate chamber or device for rotating the substrate is not required.

[0044] Note that the above-described configuration of the substrate handling mechanism 210 and its substrate rotation operation are merely examples, and other arrangements are also included in various embodiments. In one example, FIGS. 3A and 3B show that the edge 323 of the substrate 220 connecting the second portion 222 and the third portion 223 coincides with the edge 274 of the second extension portion 266. However, the substrate rotation operation can also be initiated when the edge 323 is located between the opposing edges 273 and 274 of the second extension portion 266 in the Y direction. In this specification, the edge 273 extends in the X direction and is located on the infeed side of the second extension portion 266, defining the boundary between the second extension portion 266 and the main portion 262. The edge 274 extends in the X direction on the opposite side of the edge 273 in the Y direction and is located on the outfeed side of the second extension portion 266. 3D and 3E , it is also possible to complete the substrate rotation operation with the first edge 312 of the substrate 220 positioned between the opposing edges 273 and 274 of the second extension 266, rather than coincident with the edge 274 of the second extension 266. Alternatively or in addition, the first actuator 230 and the auxiliary actuator 250 have been described as moving simultaneously before and after substrate rotation in order to move the substrate 220, which is already held by the first actuator 230 and the second actuator 240, to a position that allows it to avoid obstacles during substrate rotation.

[0045] Although the substrate 220 has been described as being transported into the printer 200 in a portrait orientation, in a further example, the substrate 220 can be transported into the printer 200 in a landscape orientation. Similarly, although the substrate 220 has been described as being discharged from the printer 200 in a portrait orientation, the substrate 220 can be discharged from the printer 200 in a landscape orientation if the post-processing chamber and / or post-processing device is configured to handle the substrate in a landscape orientation. Furthermore, the multiple movements or translations of the substrate 220 in the Y direction described above are exemplary, and more or fewer movements in the Y direction can be made, and / or printing material can be deposited in any one or more movements.

[0046] While the substrate handling mechanism 210 has been described as being located on the outfeed side, in yet another example, the substrate handling mechanism 210 could be located on the infeed side. In one configuration, the first actuator 230 is still on the same side of the work table 102 as the holder assembly 106, but is located on the infeed side of the printer 200. The second actuator 240, the secondary actuator 250, and the substrate support 260 are also located on the infeed side. In this configuration, the substrate can be introduced into the infeed side of the printer 200 while simultaneously rotating the substrate, if necessary.

[0047] Although the printer 200 has been described as including the first actuator 230 and the holder assembly 106 on the same side as the substrate support 260, in further examples, the first actuator 230 and the holder assembly 106 may be located on opposite sides of the substrate support 260. Specifically, the first actuator 230 may be located adjacent to the first extension 264, with the arm 236 extending across the entire width of the second extension 266 and the main portion 262 in the X direction to engage a corresponding corner 221 of the substrate 220.

[0048] Although the substrate handling mechanism 210 has been described as rotating the substrate 220 counterclockwise, in another example, the substrate handling mechanism 210 can be configured or controlled to rotate the substrate 220 clockwise, i.e., in the direction opposite to the rotation direction shown in Figures 3B to 3D. For example, the first actuator 230 and the second actuator 240 can initially hold the substrate 220 in a state similar to that shown in Figure 3D. Next, the first actuator 230 is controlled to move in the Y direction toward the infeed side, and the second actuator 240 is simultaneously controlled to move in the X direction toward the first actuator 230. As a result, the substrate 220 rotates to the state shown in Figure 3C, and then to the state shown in Figure 3B.

[0049] 4A and 4B are perspective views of parts of printer 200 according to at least one embodiment, and FIG. 4C is a schematic rear view of the parts.

[0050] FIG. 4A illustrates an exemplary configuration of the first actuator 230 and the second actuator 240 in more detail than FIGS. 2 and 3A-3E. Specifically, FIG. 4A illustrates that each of the first actuator 230 and the second actuator 240 includes a carriage 232, 242 coupled to and movable along a corresponding rail 234, 244, an arm 236, 246 extending from the carriage 232, 242 toward the substrate support 260, and an end effector 238, 248 pivotally coupled to the distal end of the corresponding arm 236, 246 and configured to hold a corresponding portion of the substrate 220. The arms 236, 246 are elongated members having a length generally greater than a width. A first or proximal end 411 of the arm 236 is attached to the carriage 232, and a first or proximal end 413 of the arm 246 is attached to the carriage 242. The arm 236 extends from the carriage 232 toward the substrate support 260 such that a second or distal end 415 of the arm 236, when properly positioned, is positioned above the substrate support 260 and provides access to the first portion 221 of the substrate 220. The arm 246 extends from the carriage 242 toward the substrate support 260 such that a second or distal end 417 of the arm 246, when properly positioned, is positioned above the substrate support 260 and provides access to the second portion 222 of the substrate 220. The second ends 415, 417 of the arms 236, 246 are offset from the first ends 411, 413 along the length of each arm. Although the two arms 236, 246 are shown herein to extend perpendicular to each other and to their respective rails 234, 244, the arms may extend at different angles if desired.

[0051] Figure 4B shows an example configuration of the first actuator 230 in more detail than Figure 4A. Specifically, Figure 4B shows that the end effector 238 of the first actuator 230 includes a base member 431 positioned to extend above the substrate support 260 and a plurality of suction cups 432. The base member 431 is rotatably coupled to the arm 236 at a second end 415 of the arm 236 about a rotation axis 436. The rotation axis 436 is located near the second end 415 and an appropriate operational distance from the second end 415. In Figure 4B, the substrate 220 is in a state between Figures 3B and 3D, i.e., during a substrate rotation operation.

[0052] The base member 431 is coupled to the second end 415 of the arm 236 at a first end 412 of the base member 431. The suction cup 432 is attached to the base member 431 at a second end 414 of the base member 431. The suction cup 432 is aligned along the longitudinal axis 416 of the base member 431. The base member 431 is coupled to the arm 236 at a central portion such that a rotation axis 436 passes through the longitudinal axis 416 of the base member 431. The rotation axis 436 may be spaced apart from the longitudinal axis 416 of the base member 431. The suction cup 432 is attached to a holder 418. The holder 418 is attached to a ridge 420 that extends along the underside of the base member 431 in the longitudinal direction of the base member 431. The holder 418 has an attachment portion 422 that extends away from the ridge 420 toward a long edge 424 of the base member 431. The suction cups 432 are attached to mounting portions 422 of the holder 418 so that they are aligned with but spaced apart from the longitudinal axis 416. The suction cups 432 are evenly spaced apart along the longitudinal axis 416. The ridges 420 and holders 418 extend partially along the underside of the base member 431. An upright member 450 is attached to the other long edge (not numbered in FIG. 4B ) of the base member 431 opposite the long edge 424 across the longitudinal axis 416. The ridges 420 and attached holders 418 are coupled to the upright member 450 for movement along the Z direction, as will be described with reference to FIG. 4C .

[0053] FIG. 4C is a schematic rear view of upright member 450. A front view of upright member 450 is shown in FIG. 4B. In the exemplary configuration of FIG. 4C, upright member 450 has a slot 458 that is elongated in the Z direction. Protrusion 420 has a narrow portion (not shown) that extends through slot 458 and is movable along slot 458. Protrusion 420 is coupled to an actuator 460, such as a motor or servo motor. Actuator 460 is controlled, for example, by controller 270, to move protrusion 420, as well as holder 418 and suction cup 432 (best shown in FIG. 4B), up and down in the Z direction along slot 458.

[0054] Returning to FIG. 4B , the suction cup 432 is disposed on the underside of the base member 431 at a position offset from the rotation axis 436 and configured to be lowerable toward and liftable away from the substrate support 260 via the ridge 420 and holder 418 by an actuator 460, for example, as described with reference to FIG. 4C . The suction cup 432 has a corresponding port 433 for applying suction or vacuum to the suction cup 432 to engage the suction cup 432 with a corresponding portion of the substrate 220 before substrate rotation. Positive pressure can be applied via the port 433 to disengage the suction cup 432 from the corresponding portion of the substrate 220 after substrate rotation. A drive member 434 is disposed on the upper surface of the base member 431, and the drive member 434 is coupled to a rod 441 that controllably extends and retracts from an end 443 of a cylinder 435. A first pivot 452 is disposed on the upper surface of the end 443 of the cylinder 435. A post 447 is disposed on the upper surface of the arm 236. A second pivot 454 is disposed on the upper surface of the post 447. A bracket 456 is rotatably coupled between the first pivot 452 and the second pivot 454, thereby coupling the end 443 of the cylinder 435 to the post 447. Movement of the rod 441 into or out of the cylinder 435 can be controlled by, for example, the control unit 270. The second actuator 240 has a configuration and / or operation similar to that of the first actuator 230, and the following description of the operation of the first actuator 230 can also be applied to the second actuator 240.

[0055] Before the suction cup 432 engages with the substrate 220 for substrate rotation, the cylinder 435 is controlled to a pressurized state, for example, by supplying pressurized air from a pressurized air source. The rod 441 of the pressurizing cylinder 435 then retracts (or pushes) the base member 431 to a predetermined home position. At this home position, the suction cup 432 is positioned in the Y direction directly above the edge 312 of the substrate 220 to be engaged. In addition to moving the base member 431 and the suction cup 432 to the home position, the first actuator 230 and the corresponding portion 221 of the substrate 220 are further aligned. The alignment of the first actuator 230 and the corresponding portion 221 of the substrate 220 can be based on the coordinates or positions of the corners of the substrate 220. The coordinates or positions of the corners of the substrate 220 can be determined from the settings of the printer 200 and / or detected by a camera using image processing techniques, as described with reference to FIG. 3A . For example, after the base member 431 and the suction cups 432 have moved to the home position, the carriage 232 is controllably moved along the rails 234 to align the rotation axis 436 based on the detected coordinates or positions of the corners of the substrate 220 so that the detected corners 421 of the substrate 220 in the first portion 221 coincide with the rotation axis 436. As a result of the above-described movement of the base member 431 and the suction cups 432 to the home position and the above-described alignment of the rotation axis 436 with the corners 421 of the substrate 220, the suction cups 432 are aligned with peripheral non-printing areas 437 along the edge 312 of the substrate 220. The non-printing areas 437 are areas of the substrate 220 where no printing material is deposited, unlike the printing areas 438 of the substrate 220 where printing material is deposited. The non-printing areas 437 extend around the printing areas 438 along the periphery of the substrate 220. The dimensions and / or location of the non-printing areas 437 relative to the corners of the substrate 220 are included in the setup of the printer 200 for each individual substrate 220 and / or each print job. Once aligned, the suction cup 432 is lowered closer to the substrate support 260 and a vacuum or suction force is applied to the port 433 to engage the suction cup 432 with the top surface of the substrate 220 along the non-printing areas 437.Engagement of the suction cups 432 with the non-printed areas 437 avoids or reduces damage to printed features present in or deposited in the printed areas 438. Before and during engagement of the suction cups 432 with the non-printed areas 437, the holder assembly 106 holds the substrate 220 by vacuum or suction applied to the underside of the substrate 220 through holes 406 in the holder assembly 106. In one configuration, the holes 406 are located in areas on the order of a few millimeters wide along the longitudinal edges (in the Y direction) of the holder assembly 106. The non-printed areas 437 overlap at least some of the holes 406 before and after the substrate rotation operation, for example, when the substrate 220 is in the states described with respect to one or more of Figures 3A, 3B, 3D, and 3E. Once the suction cups 432 of the first actuator 230 have engaged with the non-printed region 437, and the suction cups (not shown) of the second actuator 240 have similarly aligned and engaged with the corresponding portions (not shown) of the non-printed region 437, the holder assembly 106 is controlled to release the substrate 220 by applying positive pressure to the holes 406. As a result, the substrate 220 is maintained on the support surface 110 by the substrate handling mechanism 210 in the state shown in FIG. 3A . The first actuator 230 and the auxiliary actuator 250 are then controlled to move the substrate 220 to the state shown in FIG. 3B . The cylinder 435 is then controlled to a depressurized state, for example, by shutting off the supply of pressurized air, so that the rod 441 of the depressurized cylinder 435 is free to move along the cylinder 435. As a result, the end effector 238 is free to rotate with the substrate 220 during a subsequent substrate rotation operation performed by simultaneously moving the first actuator 230 and the second actuator 240 as described herein. Once the substrate rotation operation is complete, the holder assembly 106 is controlled to engage the substrate 220 along the second edge 341, for example, in the state shown in Figure 3E. Once engagement of the holder assembly 106 with the second edge 341 is complete, the application of vacuum or suction force to the port 433 is stopped (or a positive pressure is applied to the port 433), releasing the suction cup 432 from the non-printing area 437. The suction cup 432 is then raised to disengage the end effector 238 from the substrate 220 and avoid interference with subsequent movement of the substrate 220.A similar disengagement occurs between the suction cups (not shown) of the second actuator 240 and corresponding portions (not shown) of the non-print area 437 .

[0056] 4B , simply by applying pressure to the cylinder 435 to move the base member 431 and suction cup 432 to a predetermined home position, the suction cup 432 can be easily aligned with the edge of the substrate to be engaged for the substrate rotation operation. Furthermore, simply by applying pressure to the cylinder 435 at the beginning of the substrate rotation operation, the end effector 238 is free to rotate with the substrate 220 during the substrate rotation operation. As a result, a simple yet effective substrate rotation configuration can be achieved.

[0057] 5A and 5B are elevated side views of the outfeed side of printer 200 according to at least one embodiment. FIG. 5A is an elevation view from the Y direction, and FIG. 5B is an elevation view from the X direction. In FIG. 5A, rail 234 is attached to support 534, and rails 254A and 254B are attached to supports 554A and 554B, respectively. Supports 534, 554A, and 554B have their upper ends attached to the undersides of rails 234, 254A, and 254B, respectively. The lower ends of supports 534 and 554A are attached to mounting structure 555A, and the lower end of support 554B is attached or secured to mounting structure 555B. As best seen in FIG. 5B, mounting structure 555B is attached or secured to base 108. Mounting structure 555A (not shown in FIG. 5B) is likewise attached or secured to base 108. In Figure 5A, arm 236 of first actuator 230 extends in the X direction from carriage 232 past holder assembly 106, with end effector 238 positioned above substrate support 260 (not numbered in Figure 5A). In Figure 5B, arm 246 of second actuator 240 extends in the Y direction from carriage 242 past rails 254B and 254A (not shown in Figure 5B), with end effector 248 positioned above substrate support 260.

[0058] 5A and 5B, the movable portion of carriage 232 mounted on rail 234 and / or the movable portion of carriage 242 mounted on rail 244 and / or the movable portion of carriage 252 (not numbered in FIGS. 5A and 5B) mounted on rail 254A are positioned outside the installation area of ​​substrate 220 and below the upper surface of substrate support 260 on which substrate 220 is supported by a gas cushion. As a result, in at least one embodiment, it is possible to minimize the possibility that particles generated by the movable portion will collide with the surface of substrate 220.

[0059] As described herein, the substrate handling mechanism in the printer allows for in-situ substrate rotation without the need for a separate chamber or device for rotating the substrate, thereby reducing the overall processing time and reducing the cost and footprint of a separate rotation chamber and / or device.

[0060] 6 is a flowchart of a method for manipulating a substrate in a printer according to at least one embodiment. Method 600 can be implemented in any of printing systems 100, 200 by or under the control of at least one controller described herein.

[0061] In operation 605, the substrate is supported on a substrate support, for example, substrate 220 on substrate support 260 of substrate handling mechanism 210 of printer 200, as described with respect to Figure 3B.

[0062] In operation 615, a first portion of the substrate is held by a first end effector of a first actuator. The first end effector is rotatable about a first axis of rotation. For example, as described with respect to FIGS. 2, 3A, 3B, 4A, and 4B, a first portion 221 of the substrate 220 is held by an end effector 238 of a first actuator 230 of the substrate handling mechanism 210. The end effector 238 is rotatable about a first axis of rotation 436 relative to an arm 236 of the first actuator 230. In one example, the axis of rotation 436 is aligned with a corner 421 of the substrate 220.

[0063] In operation 625, a second portion of the substrate is held by a second end effector of a second actuator. The second end effector is rotatable about a second axis of rotation. For example, as described with respect to FIGS. 2, 2A, 3A, 3B, and 4A, a second portion 222 of the substrate 220 is held by an end effector 248 of a second actuator 240 of the substrate handling mechanism 210. The end effector 248 is rotatable about the second axis of rotation relative to an arm 246 of the second actuator 240. In one example, the second axis of rotation of the end effector 248 is aligned with a second corner of the substrate 220 in a manner similar to that described with respect to the first actuator 230.

[0064] In operation 635, the first and second actuators are simultaneously moved in a first direction and a second direction intersecting the first direction, respectively, to rotate the substrate from the first orientation to the second orientation. For example, as described with respect to Figure 3C, the first and second actuators 230 and 240 are simultaneously moved in the Y and X directions, respectively, to rotate the substrate 220 from the portrait orientation of Figure 3B to the landscape orientation of Figure 3D. As a result, in-situ rotation of the substrate within the printer 200 is possible, providing one or more of the advantages described herein.

[0065] In at least one embodiment, printed products produced with the above-described printing methods and / or printers include, but are not limited to, solar panels, flat panel displays such as organic light emitting diode (OLED) displays, and the like.

[0066] The methods described above include example operations that do not necessarily need to be performed in the order described. Operations may be added, substituted, reordered, and / or deleted as needed in accordance with the spirit and scope of the embodiments of the present disclosure. Embodiments that combine different features and / or different embodiments are also within the scope of the present disclosure and would be apparent to one of ordinary skill in the art upon review of the present disclosure.

[0067] Figure 7 is a block diagram of a controller according to at least one embodiment. One or more of the units and / or systems and / or operations described with respect to Figures 1-6 are implemented, in one embodiment, by one or more controllers 700 of Figure 7.

[0068] The controller 700 includes a hardware processor 702, a storage device 704 including at least one non-transitory computer-readable storage medium, a bus 708, an I / O (input / output) interface 710, and a network interface 712. The processor 702 is coupled to the storage device 704, the I / O interface 710, and the network interface 712 via the bus 708. The network interface 712 is connectable to a network 714, thereby enabling the processor 702 and the storage device 704 to communicate with other devices via the network 714. The processor 702 is configured to execute computer program instructions encoded in and / or access data stored in the storage device 704 to cause the controller 700 to perform one or more functions and / or operations described with respect to FIGS.

[0069] The processor 702 may include one or more of a central processing unit (CPU), multiprocessor, distributed processing system, application specific integrated circuit (ASIC), and / or suitable hardware processing unit.

[0070] Storage device 704 includes one or more electronic, magnetic, optical, electromagnetic, infrared, and / or semiconductor systems (or apparatus or devices) for non-transient storage of instructions and / or data. For example, storage device 704 includes semiconductor or solid-state memory, magnetic tape, removable computer diskettes, random access memory (RAM), read-only memory (ROM), rigid magnetic disks, and / or optical disks. Examples of optical disks, storage device 704 includes compact disc-ROM (CD-ROM), rewritable compact disc-R / W (CD-R / W), and / or digital video disks (DVD).

[0071] I / O interface 710 is a circuit that can be connected to external circuitry. For example, I / O interface 710 includes one or more of a keyboard, keypad, mouse, trackball, trackpad, cursor direction keys, card reader, communication port, display, signal lights, printer, and / or audio device for communicating information to and from processor 702. In one example, I / O interface 710 is omitted.

[0072] The network interface 712 is circuitry that enables the controller 700 to communicate with a network 714 to which one or more other controllers and / or image acquisition / processing devices are connected. For example, the network interface 712 includes one or more of a wireless network interface such as BLUETOOTH, WIFI, WIMAX, GPRS, WCDMA, etc., or a wired network interface such as ETHERNET, USB, IEEE-1394, etc. In one example, the network interface 712 is omitted.

[0073] The control unit 700 is configured to perform some or all of the functions and / or operations described with respect to Figures 1 to 6, and may therefore achieve one or more of the benefits and / or effects described with respect to Figures 1 to 6.

[0074] The foregoing outlines features of several embodiments so that those skilled in the art may better understand aspects of the present disclosure. Those skilled in the art will appreciate that this disclosure may readily be used as a basis for designing or modifying other processes and structures which carry out the same purposes and / or achieve the same advantages as the embodiments described herein. Those skilled in the art will also appreciate that such equivalent constructions do not depart from the spirit and scope of the present disclosure, and that various changes, substitutions, and alterations can be made thereto without departing from the spirit and scope of the present disclosure.

Claims

1. A printer, the printer comprising: a gas cushion substrate support supporting a substrate above a surface of the substrate support; a printhead assembly for depositing printing material onto the substrate supported on the substrate support; a holder assembly for positioning the substrate supported on the substrate support relative to the printhead assembly; a substrate manipulation mechanism; The substrate manipulation mechanism includes a first actuator arranged on a first linear track extending in a first direction and a second actuator arranged on a second linear track extending in a second direction perpendicular to the first direction, each actuator having a rotatable end effector coupled to an upper surface of the substrate and rotating with the substrate as the first and second actuators move along their respective tracks.

2. 10. The printer of claim 1, wherein each end effector comprises a plurality of suction cups having a plurality of ports for applying a suction force to the substrate.

3. 3. The printer of claim 2, wherein each suction cup is connected to both a vacuum source and a source of pressurized air.

4. 10. The printer of claim 1, wherein each actuator further comprises a pressure cylinder coupled to a respective end effector for moving the end effector to a home position.

5. 10. The printer of claim 1, wherein the holder assembly and the first actuator are located to one side of the substrate support.

6. 10. The printer of claim 1, wherein the substrate handling mechanism further comprises at least one auxiliary actuator for positioning the second actuator into engagement with the substrate.

7. 10. The printer of claim 1, further comprising a controller configured to cooperatively move the first actuator and the second actuator to rotate the substrate.

8. 10. The printer of claim 1, wherein each of the first and second actuators comprises a carriage and an arm attached to the carriage at a first end, the arm extending above the substrate support and coupled to the end effector at a second end opposite the first end.

9. 9. The printer of claim 8, wherein each end effector comprises a base member attached to the arm of the actuator at the first end, and a plurality of suction cups attached to the base member at a second end opposite the first end and detachable from the substrate.

10. 10. The printer of claim 1, wherein the substrate support comprises: A rectangular main portion; a first extension portion adjacent to the main portion in the second direction and configured to support a first corner portion of the substrate when the substrate is rotated; a second extension portion adjacent to the main portion in the first direction and supporting a second corner portion of the substrate when the substrate is rotated; A printer in which the main portion, the first extension, and the second extension all provide gas cushion substrate support.

11. A printer, the printer comprising: a gas cushion substrate support for supporting a substrate above a surface of a substrate support, the gas cushion substrate support having a main portion that supports the substrate during movement of the substrate and first and second extension portions that support the substrate during rotation of the substrate; a printhead assembly for depositing printing material onto the substrate; a holder assembly for positioning the substrate supported on the substrate support relative to the printhead assembly for processing by the printhead assembly; the substrate handling mechanism including a first actuator movably disposed on a first linear track extending in a first direction and a second actuator movably disposed on a second linear track extending in a second direction perpendicular to the first direction, each actuator including a rotatable end effector with a suction cup coupleable to an upper surface of the substrate and rotating with the substrate as each actuator moves along its respective track, the suction cups being liftable.

12. 12. The printer of claim 11, wherein each of the first and second actuators comprises: A printer comprising: a carriage; and an arm having a first end attached to the carriage and a second end extending above the substrate support and attached to the end effector.

13. 12. The printer of claim 11, further comprising a controller configured to coordinate operation of the first actuator and the second actuator to rotate the substrate.

14. 13. The printer of claim 12, wherein each actuator further comprises a pressure cylinder coupled to a respective end effector for moving the end effector to a home position.

15. 13. The printer of claim 12, wherein each end effector comprises a base member rotatably attached to the arm at a first end of the base member, the suction cup attached to the base member at a second end opposite the first end.

16. 16. The printer of claim 15, wherein the arm is attached to a first surface of the base member, and the suction cup is attached to a second surface of the base member opposite the first surface.

17. 12. The printer of claim 11, wherein the holder assembly moves the substrate in the first direction, and the second linear track is movable relative to the first direction.

18. A printer, the printer comprising: a gas cushion substrate support for supporting a substrate above a surface of a substrate support, the gas cushion substrate support having a main portion that supports the substrate during movement of the substrate and first and second extension portions that support the substrate during rotation of the substrate; a printhead assembly for depositing printing material onto the substrate; a holder assembly for positioning the substrate supported on the substrate support relative to the printhead assembly for processing by the printhead assembly; the substrate handling mechanism comprising a first actuator movably disposed on a first linear track extending in a first direction and a second actuator movably disposed on a second linear track extending in a second direction perpendicular to the first direction, each actuator comprising a rotatable end effector with a suction cup coupleable to an upper surface of the substrate and rotating with the substrate as each actuator moves along its respective track, the suction cups being liftable.

19. 20. The printer of claim 18, wherein the suction cup is connected to both a vacuum source and a pressurized gas source.

20. 20. The printer of claim 18, wherein the holder assembly is configured to contact an underside of the substrate, and wherein the holder assembly and the end effector of the first actuator are capable of contacting the substrate simultaneously.

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