External Reference Pattern for Large-Surface Inkjet Printing
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Solution Overview
Problem
Current inkjet printing technologies struggle to achieve high positional accuracy on large, complex, and irregular surfaces, such as those found on vehicles and aircraft, leading to errors and increased operational costs due to the need for masking and multiple paint/cure cycles.
Innovation Solution
A large-area printing system that uses a projector to create a pattern on the surface, allowing the print head to be precisely positioned using image acquisition devices and control circuitry, enabling the deposition of seamless graphic outputs by aligning each portion of the image with the projected pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If inkjet printing is used on complex surfaces, then productivity is improved by eliminating masking requirements, but manufacturing precision deteriorates due to difficulty in accurately positioning on irregular surfaces
Solution Approach 1:
The patent introduces an encoder pattern as an intermediary reference system that is projected onto or applied to the complex surface. This encoder pattern serves as a mediator between the print head positioning system and the irregular surface, enabling accurate localization and alignment without requiring physical masking. The encoder pattern provides detectable reference points that allow the system to compensate for surface complexity while maintaining high printing precision and productivity.
2Manufacturing precision
If manual masking is used to ensure printing accuracy on complex surfaces, then manufacturing precision is improved, but productivity deteriorates due to time-consuming operations and multiple paint cycles
Solution Approach 1:
The patent replaces the mechanical masking process with an optical/digital positioning system. Instead of physically applying masking materials to define print boundaries, the system uses projected encoder patterns and image acquisition devices to optically detect surface geometry and computationally determine precise print head positioning. This substitution eliminates the need for manual masking operations and multiple paint/cure cycles, thereby maintaining printing accuracy while dramatically improving productivity.
3Manufacturing precision
If current inkjet printing technology is used on flat surfaces, then manufacturing precision is maintained, but adaptability deteriorates when attempting to print on curved or complex surfaces
Solution Approach 1:
The patent implements a dynamic positioning system that adapts to varying surface geometries in real-time. The system uses image acquisition devices to continuously detect the encoder pattern on complex surfaces and dynamically adjusts print head position and orientation accordingly. This dynamic adaptation allows the system to maintain high printing resolution across flat, curved, and irregular surfaces, significantly improving versatility while preserving manufacturing precision.
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 significantly improves positional accuracy, allowing for seamless graphic images on complex surfaces with reduced errors and operational costs by eliminating the need for masking and multiple paint cycles, while maintaining high printing resolution.
Implementation Method 1
at least one pattern projector to project a pattern on a surface
Implementation Method 2
at least one image acquisition device to obtain image data representative of the projected pattern proximate the print head
Data Source
Figure 1
Figure 2A~2B
Figure 3
AI summary
It is often desirable to apply graphic output to surfaces that are large, irregular, and/or contoured. Application of graphic output on large or complex surfaces may be accomplished by projecting a pattern onto the surface using a projector disposed at a fixed location with respect to the surface. The graphic output is mapped to the projected pattern, by precisely positioning the print head with respect to the projected pattern using a robotic or similar actuated articulated positioning device, graphic output portions may be disposed in each of a plurality of defined locations to form a seamless, large scale graphic output.