Ink Jetting With Aligned Variable-Size Drops
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Solution Overview
Problem
Ink jetting technologies face challenges in achieving high resolution and quality printing due to misalignment and differences in properties between printheads, leading to streaks and image artifacts, especially when printing across a wide substrate.
Innovation Solution
The use of multiple jetting assemblies with aligned jets capable of jetting fluid drops of varying sizes, where each jet can produce drops of 30, 50, or 80 nano-grams, and overlapping arrays to ensure seamless pixel formation and reduce quality issues by compensating for misalignment and property differences.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If multiple printheads are used to cover wide substrate, then printing coverage is improved, but misalignment and image artifacts increase
Solution Approach 1:
The system divides the printing task into multiple segments by using multiple printheads (first printhead with first array of jets, second printhead with second array of jets) that operate independently on different portions of the substrate. Each printhead can be optimized for its specific region, and they work in parallel to cover the entire wide substrate area without requiring perfect alignment between them.
Solution Approach 2:
The patent transitions from single-printhead operation to multi-printhead operation, adding spatial dimensionality to the printing system. By arranging printheads in arrays and using overlapping jet patterns, the system covers wider areas while maintaining quality through dimensional distribution of the printing function.
2Productivity
If larger ink drops are used to cover pixels, then printing speed is improved, but resolution and image quality deteriorate
Solution Approach 1:
Each pixel is segmented into multiple smaller ink drops instead of using a single large drop. The system can jet multiple smaller drops (e.g., five 10-picoliter drops) to collectively form one pixel, achieving both high resolution (precise drop placement) and high speed (parallel jetting from multiple printheads and jets).
Solution Approach 2:
The system changes the parameter of ink drop size from fixed large drops to variable small drops. By controlling drop size and number dynamically, the system can adjust between speed and resolution requirements for different printing scenarios, using smaller drops for high-resolution areas and coordinating multiple drops for faster coverage.
3Manufacturing precision
If smaller ink drops are used to achieve high resolution, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The patent merges the output of multiple printheads and multiple jets within each printhead to achieve high-speed printing with small drops. By combining the jetting capabilities of many individual jets working in parallel, the system produces the equivalent of large-coverage printing using only small, high-resolution drops, thus maintaining both precision and productivity.
Solution Approach 2:
The system performs preliminary planning of drop placement patterns before actual jetting. By pre-determining which jets will jet small drops and coordinating their timing and positioning, the system optimizes the sequence of small-drop jetting to maximize printing speed while maintaining resolution, avoiding redundant movements and optimizing drop placement efficiency.
Data Source
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AI summary
Among other things, for jetting fluid droplets on a substrate during relative motion of an apparatus and the substrate along a process direction, a first and second jetting assemblies at least partially overlap in a direction perpendicular to the process direction so that some jets in the first jetting assembly align with some jets in the second jetting assembly along the process direction to form one or more pairs of aligned jets. A mechanism enables, in at least one pair of the aligned jets, one jet to jet a first fluid drop that has a size smaller than a size of a fluid drop the jet would otherwise be required to jet to form a desired pixel and the other jet to jet a second fluid drop that has a size sufficient to form the desired pixel in combination with the first fluid drop.