Inkjet Print System Height-Compensated Coating Control
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Solution Overview
Problem
Inkjet printing technologies face challenges in forming a desired coating layer due to non-uniform ejection, ink spread, and curing contraction, which affect the quality of the coating layer before it is fully cured.
Innovation Solution
An inkjet print system with a stage, inkjet head, measurement instrument, and processor that adjusts ink ejection based on height measurements to ensure precise control over ink distribution and ejection, allowing for real-time adjustments in ejection amount and starting position to achieve a desired coating shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional inkjet printing is used to form a coating layer, then the printing process is simple, but the coating layer shape is distorted due to non-uniform ejection, ink spread, and curing contraction
Solution Approach 1:
The system performs preliminary measurement of the substrate surface height before inkjet printing and pre-calculates the compensation map. By determining the required ink ejection amount for each nozzle in advance based on the measured surface topology, the system compensates for expected deformations before they occur, ensuring accurate coating layer formation without requiring complex real-time adjustments during printing
Solution Approach 2:
The system implements a feedback loop where the measured substrate surface height information is fed back to the processor, which then adjusts the ink ejection parameters for each nozzle accordingly. This closed-loop control allows the system to automatically compensate for surface variations and achieve uniform coating layers despite substrate irregularities
2Productivity
If ink is ejected to form a coating layer, then the coating can be applied efficiently, but the ink spreads and deforms before curing
Solution Approach 1:
The system applies different ink ejection parameters to different locations on the substrate by controlling each nozzle independently. By adjusting the ink ejection amount, droplet size, and ejection timing for each specific nozzle based on the local substrate height and required coating thickness, the system prevents ink spread and deformation while maintaining efficient coating application
Solution Approach 2:
The system dynamically changes ink ejection parameters including droplet size, ejection speed, and ink composition for different regions of the substrate. By modifying these parameters based on measured surface characteristics and desired coating outcomes, the system achieves precise shape control while maintaining high productivity
3Manufacturing precision
If the ink ejection amount is increased to compensate for curing contraction, then the coating thickness is sufficient, but the coating layer becomes non-uniform
Solution Approach 1:
The system divides the coating process into discrete segments by controlling each nozzle independently with customized ink ejection parameters. By segmenting the substrate into multiple zones and applying different ink amounts to each zone based on local requirements, the system achieves uniform coating thickness without excessive ink consumption that would result from uniform over-compensation
Data Source
AI summary
Disclosed are an inkjet print system and an inkjet printing method using the same. An inkjet print system according to one embodiment of the disclosure may include a stage on which a printing medium is loaded and which moves the printing medium in a first direction, an inkjet head which moves in a second direction perpendicular to the first direction and in which a plurality of nozzles configured to eject an ink on the printing medium are formed, a measurement instrument which moves in the second direction independent of the inkjet head and measures a height for each section of an impacted coating layer on the printing medium, and a processor which allows the nozzles to be opened or closed on the basis of height information of the coating layer.