Variable Duration DotClock Signal Generator for Sintering Head
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Solution Overview
Problem
Existing printing systems face challenges in accurately synchronizing the activation of sintering head lamps, which require sustained illumination for varying circuit lengths, while traditional DotClock signals are time-based and do not account for different illumination periods, leading to errors in circuit trace formation.
Innovation Solution
A method and system that modify the DotClock signal generator to produce activation signals with variable durations by setting a distance between signal generations and adjusting signal duration to maintain the active state until the next signal is reached, using positional data from encoders to ensure precise exposure of substrates to sintering head radiation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional DotClock signals are used for sintering head activation, then the signal generation is simple and time-based, but the signal duration cannot be varied to match different circuit lengths, leading to exposure errors
Solution Approach 1:
The patent applies dynamics by making the signal duration variable rather than fixed. The DotClock signal generator is modified to dynamically adjust the duration of activation signals based on the detected circuit length, allowing the same generator to adapt to different substrate configurations without requiring multiple specialized generators.
Solution Approach 2:
The patent changes the duration parameter of the DotClock activation signal from a fixed value to a variable value that corresponds to different circuit lengths. This parameter change allows the signal to adapt to varying substrate requirements while maintaining compatibility with the existing signal generator architecture.
2Manufacturing precision
If the signal duration is extended to cover the entire circuit exposure period, then the exposure accuracy is improved, but the signal must be maintained at activating amplitude for longer periods, increasing energy consumption
Solution Approach 1:
The system dynamically adjusts the signal duration to match the exact exposure period required for each circuit length, avoiding unnecessary extended signal transmission. The signal is maintained at activating amplitude only for the duration needed to cover the circuit exposure, reducing wasted energy while ensuring complete coverage.
Solution Approach 2:
The system uses feedback from the substrate transport position and circuit length detection to determine the appropriate signal duration. This feedback mechanism ensures the activation signal is transmitted for the precise period needed, neither too short to cause exposure errors nor too long to waste energy.
3Adaptability or versatility
If the DotClock signal generator is significantly altered to produce variable duration signals, then the adaptability to different circuit lengths is improved, but the complexity and cost of modification increases
Solution Approach 1:
The modified DotClock signal generator is designed to perform multiple functions: it can generate activation signals for both printheads and sintering heads, and it can adjust signal duration based on the application requirements. This multi-functionality reduces the need for separate specialized generators and simplifies the overall system architecture.
Solution Approach 2:
The system performs preliminary detection of the circuit length and substrate position before generating the activation signal. This preliminary action allows the signal generator to be configured with the appropriate duration in advance, avoiding the need for complex real-time adjustments during signal transmission and simplifying the generator design.
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
This approach allows for accurate and precise formation of electrical circuit traces on flexible substrates with variable lengths without requiring significant alterations to existing inkjet ejector activation signal generators, maintaining signal amplitude until the entire circuit is exposed, thus improving the resolution and accuracy of printed circuits.
Implementation Method 1
a sintering head that exposes the liquid ink image to an intense light that hardens the liquid ink and bonds the traces to the substrate
Data Source
AI summary
A method of operating a printer enables activation signals of variable lengths to be generated for operation of a sintering head. The activation signals are generated with reference to a distance between activation signals for a first component to be a first determined distance and a duration of the activation signals for the first component to be longer than the first predetermined distance. This distance and duration are set to values that enable the generation of activation signals before the first predetermined distance is reached to maintain an activation signal until the generation of the activation signals is terminated. By generating a different number of activation signals, the duration of an initial activation signal can be varied.