Droplet Deposition Nozzle Misalignment Compensation

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Solution Overview

Problem

Existing droplet deposition apparatuses, such as inkjet printers, face challenges in maintaining accurate alignment between nozzle arrays, leading to visible faults like light or dark bands in the printed image.

Innovation Solution

The apparatus determines and stores the best aligned nozzle pairs in the overlap region between head modules, along with corresponding skew angles and positional offsets, to minimize misalignment and improve print quality.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If mechanical alignment methods are used to align nozzle arrays, then alignment precision is improved, but time consumption and manufacturing cost increase

Engineering Contradiction:

Improvealignment precisionVSAvoidtime consumption

Core Design Contradiction:

Manufacturing precisionVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-determining the misalignment parameters (skew angles and positional offsets) during the manufacturing process and storing them in a lookup table. This allows the alignment information to be prepared in advance, eliminating the need for time-consuming mechanical alignment adjustments during operation or installation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces mechanical alignment methods with a data-driven approach. Instead of using mechanical tools to physically align nozzle arrays, the system uses pre-calculated misalignment parameters stored in memory, which are then applied through software control to compensate for misalignment, thereby substituting mechanical adjustment with informational compensation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Manufacturing precision

If mechanical alignment methods are used to align nozzle arrays, then alignment precision is improved, but manufacturing cost increases

Engineering Contradiction:

Improvealignment precisionVSAvoidmanufacturing cost

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent replaces expensive mechanical alignment equipment and processes with a computational approach. Misalignment parameters are determined through calculations and stored in a lookup table, eliminating the need for costly mechanical alignment tools and skilled manual adjustment processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent uses a cost-effective data structure (lookup table in memory) instead of expensive mechanical alignment systems. The misalignment compensation information is stored as digital data that can be easily updated and accessed, providing a low-cost alternative to permanent mechanical alignment solutions.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Area of stationary object

If nozzle arrays are arranged in overlapping parallel configuration, then coverage width is improved, but visible faults increase

Engineering Contradiction:

Improvecoverage widthVSAvoidvisible faults

Core Design Contradiction:

Area of stationary objectVSObject-affected harmful factors

Solution Approach 1:

The patent changes the parameters used to describe and compensate for misalignment between overlapping nozzle arrays. By determining skew angles and positional offsets and storing them as compensable parameters, the system can mathematically correct the visible faults that arise from manufacturing tolerances in overlapping configurations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements a feedback mechanism where misalignment parameters are determined, stored, and then used to guide the droplet deposition process. This closed-loop approach allows the system to compensate for the visible faults created by overlapping nozzle arrays, ensuring accurate image reproduction despite the inherent misalignment in parallel overlapping configurations.

Inventive Principle:

Principle #23Feedback

Data Source

PatentUS12263679B2Droplet deposition apparatus and methods for determining misalignment thereof

Publication Date: 2025.04.01 XAAR TECH LTD

AI summary

A droplet deposition apparatus (1) comprising: a first head module (101A, 101B, 102A) and a second head module (101B, 102A, 102B) arranged in at least partially overlapping relationship, each head module having a plurality of nozzles in at least one nozzle array (A1, B1); and a storage (200) configured to store a table of determined best aligned nozzle pairs in an overlap region and corresponding skew angles (Θi) of at least one of the head modules relative to a datum of the droplet deposition apparatus and/or a corresponding positional offset of the second head module relative to the first head module; wherein, in the overlap region, nozzles of the first head module are arranged at a first nozzle pitch (P2) and nozzles of the second head module are arranged at a second nozzle itch (P3). Associated methods in respect of determining misalignment information in respect of such a droplet deposition apparatus, and determining one or more best aligned nozzle pairs in an overlap region between at least two head modules, are also provided.