Alternating Small Head Modules for Line Head Ink Supply
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Solution Overview
Problem
Existing image forming apparatuses with line heads face issues of high production costs, low yield, and the need for entire head replacement due to nozzle damage or ink cartridge depletion, along with complex ink supply and wiring configurations.
Innovation Solution
An image forming apparatus with a configuration of alternately arranged small heads in the width direction of a recording medium, allowing for individual head replacement and a common ink path supplied from one side, reducing the width of the line head and simplifying the ink supply system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a long line head is used to cover the entire width of the recording medium, then high-speed image formation is achieved, but the production yield decreases and manufacturing cost increases
Solution Approach 1:
The long line head is divided into multiple small head chips that are arranged alternately in the width direction of the recording medium. Each small head chip can be manufactured separately with higher yield, and when assembled together they form a virtual long line head that spans the entire width, enabling high-speed image formation without the manufacturing drawbacks of a single long head
2Ease of manufacture
If multiple small heads are arranged alternately to form a virtual line head, then production yield improves, but the complexity of ink supply paths and control wiring increases
Solution Approach 1:
Multiple ink supply paths are merged into a common ink supply path that is shared by all small head chips. The ink supply mechanism is unified so that a single ink cartridge or reservoir can supply ink to all heads through this common path, significantly reducing the complexity of ink supply infrastructure while maintaining the benefits of multiple separate heads
3Reliability
If the entire line head must be replaced due to nozzle damage, then reliability is maintained, but loss of time and operational efficiency decrease
Solution Approach 1:
The line head is segmented into multiple independently replaceable small head chips. When a nozzle or head chip fails, only the defective small head chip needs to be replaced rather than the entire line head assembly. This segmentation enables rapid replacement of individual faulty components while maintaining the functionality of other head chips, significantly reducing downtime and improving operational efficiency
4Device complexity
If a common ink path is used for multiple heads, then device complexity is reduced, but the interval between colors increases
Solution Approach 1:
The small head chips are arranged alternately in the width direction of the recording medium rather than sequentially in the conveying direction. This alternating arrangement in the width dimension allows the common ink supply path to serve all heads more efficiently, reducing the interval between color applications while maintaining the simplicity of the common ink supply system
Data Source
AI summary
An image forming apparatus has a recording head portion constituted of head modules having a configuration in which a plurality of small heads are detachably attached in a head mount at alternate positions in a recording medium width direction and a drive portion is also mounted.