Single-pass Imaging Apparatus with Image Data Scrolling
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Solution Overview
Problem
Current laser imaging systems face challenges in achieving high resolution and high power imaging across large areas in a single pass, due to limitations in optical performance, power levels, and hardware constraints, which restrict their application in high-speed printing and lithographic processes.
Innovation Solution
The use of a spatial light modulator with a two-dimensional array of light modulating elements, synchronized with an anamorphic optical system, to modulate and concentrate a homogenous light field, allowing for high power imaging in a single pass without requiring high power laser sources, and enabling efficient data shifting to prevent image smearing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single laser head motorized x-y flatbed architecture is used, then large area coverage is achieved, but imaging speed becomes too slow for high speed printing processes
Solution Approach 1:
The imaging system is divided into multiple independent imaging heads arranged in a array, each capable of simultaneous operation. This segmentation allows parallel processing of different regions of the imaging area, maintaining large area coverage while dramatically increasing imaging speed through concurrent operations.
Solution Approach 2:
The system transitions from single-point scanning (1D movement) to multi-point parallel imaging (2D array of simultaneous operations). By distributing imaging heads across the imaging area, the system achieves both large area coverage and high speed through spatial parallelization.
2Area of stationary object
If monolithic LED arrays are used, then large width xerography is enabled, but power levels are limited to 10 milliWatt per pixel
Solution Approach 1:
The imaging system uses separate imaging heads for different functional requirements. High-power laser heads are dedicated to high-power applications like texturing and cutting, while LED heads handle lower-power xerography applications. This segmentation allows each component to be optimized for its specific power range without compromising overall system capability.
Solution Approach 2:
The imaging system integrates multiple types of light sources (high-power lasers and LEDs) within a unified platform, enabling a single system to perform diverse functions ranging from low-power xerography to high-power texturing and cutting, thus achieving multi-functionality across different power levels and applications.
3Power
If high power semiconductor laser arrays are used, then power levels of 100 mW-100 Watts are achieved, but laser pitch between nearest neighbors cannot be compatible with 600 dpi or higher imaging resolution
Solution Approach 1:
The system segments the imaging function across multiple independent imaging heads, each capable of operating at high resolution. This allows high-power laser heads to be positioned with sufficient spacing to maintain 600 dpi or higher resolution, while the collective array achieves the required total power level through parallel operation of multiple heads.
4Area of stationary object
If arrayed imaging systems are arranged side by side to form overlapping projected images, then larger images can be stitched together, but either two rows of imaging subsystems or double pass scanning configuration is required
Solution Approach 1:
The system uses a single row of imaging heads arranged in a linear array, eliminating the need for complex two-row configurations. Each head in the array contributes to imaging a different region, and the results are combined to form the complete image, achieving large image coverage with simpler hardware architecture.
Solution Approach 2:
Multiple imaging heads are merged into a single integrated array that operates simultaneously. The imaging data from all heads is combined and stitched together to form the complete image, achieving large area coverage through horizontal arraying rather than requiring vertical stacking or double-pass scanning.
5Manufacturing precision
If all data rasters in the array change simultaneously while the imaging surface moves, then image features may smear, but synchronization increases complexity
Solution Approach 1:
The system performs preliminary synchronization setup by establishing the relationship between data raster changes and imaging surface movement before actual imaging occurs. This pre-establishment of timing relationships ensures that image features remain stationary relative to the imaging surface during the imaging process, preventing smearing without requiring complex real-time adjustments.
Solution Approach 2:
The system incorporates feedback mechanisms that monitor the imaging surface movement and adjust data raster timing accordingly. This feedback control ensures that image features remain synchronized with the imaging surface position, preventing smearing while maintaining manageable system complexity through automated adjustment.
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 enables high-resolution, high-power imaging over large areas at high speeds, reducing costs by using low-power light sources and preventing image smearing, while maintaining total power transfer, thus facilitating scalable and efficient imaging applications.
Implementation Method 1
a spatial light modulator with a two-dimensional array of light modulating elements, synchronized with an anamorphic optical system, to modulate and concentrate a homogenous light field
Implementation Method 2
anamorphic optical system to modulate and concentrate a homogenous light field, allowing for high power imaging in a single pass
Data Source
AI summary
An imaging (e.g., lithographic) apparatus for generating an elongated concentrated scan image on an imaging surface of a scan structure (e.g., a drum cylinder) that moves in a process (cross-scan) direction. The apparatus includes a spatial light modulator having a two-dimensional array of light modulating elements for modulating a two-dimensional light field in response to predetermined scan image data, and an anamorphic optical system is used to anamorphically image and concentrate the modulated light onto an elongated imaging region defined on the imaging surface. To avoid smearing, movement of the imaging surface is synchronized by an image position controller with the modulated states of the light modulating elements such that image features of the scan image are scrolled (moved in the cross-scan direction) at the same rate as the cross-scan movement of the imaging surface, whereby the features remain coincident with the same portion of the imaging surface.