Compact Inkjet Printing Unit with Nested Aerosol Extraction
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Solution Overview
Problem
Existing inkjet printers face challenges in integrating compact full-color printing units with efficient aerosol extraction systems, particularly for thermal inkjet systems with small drop sizes, while maintaining a minimal footprint to facilitate integration into existing web feed systems and reducing development time and costs.
Innovation Solution
A compact printing unit design featuring a fixed maintenance chassis with movable print modules and an aerosol extraction unit under the bottom plate, incorporating aerosol extractors that extend across the media feed path, along with efficient management of electrical cabling and ink lines, allowing for printhead movement and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a compact printing unit design is used to reduce footprint, then integration into existing systems is facilitated, but aerosol extraction efficiency may be compromised
Solution Approach 1:
The aerosol extraction unit is nested underneath the maintenance chassis, with extractors positioned in the space between the bottom plate and the aerosol source. This nested configuration allows the extraction system to be integrated within the compact printing unit footprint without requiring additional external space, thereby maintaining compactness while achieving effective aerosol removal through strategically positioned extraction points.
Solution Approach 2:
The aerosol extractors are positioned in the vertical dimension underneath the maintenance chassis rather than extending horizontally. By utilizing the vertical space and positioning extractors at multiple heights (including downstream extractors below the media path), the system achieves three-dimensional aerosol capture within a compact two-dimensional footprint, effectively removing aerosol without increasing the horizontal footprint.
2Object-affected harmful factors
If aerosol extractors are positioned close to printheads for efficient extraction, then aerosol removal is improved, but device complexity increases
Solution Approach 1:
The bottom plate of the maintenance chassis serves multiple functions: it provides structural support for the maintenance modules, defines the maintenance chamber space, and simultaneously serves as the mounting structure for the aerosol extraction unit. This multi-functionality reduces the need for separate components and simplifies the overall device structure while maintaining effective aerosol extraction positioning close to the printheads.
Solution Approach 2:
The aerosol extraction unit is merged with the maintenance chassis assembly, sharing common structural elements such as the bottom plate and side bars. The extraction unit is integrated into the existing maintenance module framework rather than being a separate standalone system, which reduces overall device complexity while achieving close positioning of extractors to the printheads for effective aerosol removal.
3Productivity
If multiple print modules are integrated in a compact arrangement, then productivity is improved, but aerosol extraction for each module becomes more difficult
Solution Approach 1:
The aerosol extraction system is segmented into multiple independent extractors, each dedicated to a specific print module. The extraction unit includes upstream extractors for each printhead and downstream extractors positioned below the media path, creating separate extraction zones for each printing module. This segmentation allows each module to be serviced by its own extraction system, preventing aerosol cross-contamination between modules while maintaining high-speed printing productivity.
Solution Approach 2:
Each aerosol extractor is locally optimized for its specific position and function within the multi-module system. Upstream extractors are positioned to capture aerosol at the source for each printhead, while downstream extractors are positioned below the media path to capture aerosol after it passes through the printing zone. This local optimization ensures effective aerosol removal for each module without interfering with adjacent modules, enabling high productivity with minimal cross-contamination.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The design enables a compact configuration with efficient aerosol extraction for multiple printheads, reducing the overall footprint and facilitating integration into existing systems while maintaining print quality and reducing contamination risks.
Implementation Method 1
an air knife having a knife slot for directing a flow of air towards print media
Implementation Method 2
to disrupt aerosol trapped in a boundary layer associated with moving media
Implementation Method 3
a suction nozzle positioned upstream of the knife slot for directing aerosol into a suction channel
Data Source
AI summary
A printing unit includes: a fixed maintenance chassis having a bottom plate defining a plurality of first slots; print modules having a respective inkjet printheads extending across a media feed path; a lift mechanism for lifting and lowering the print modules relative to the media feed path; and an aerosol extraction unit mounted to an underside of the bottom plate. The aerosol extraction unit includes a plurality of aerosol extractors, which extend across the media feed path between a pair of side bars, the aerosol extractors being spaced apart along the media feed direction to define a corresponding plurality of second slots aligned with the first slots. Each print module is slidably movable through its respective first and second slots towards the media feed path into a printing position.