Inkjet Printhead Manifold With Stiffener Plate for Low-Cost Alignment
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Solution Overview
Problem
Existing modular inkjet printing systems face challenges with long print zones, alignment issues, and high costs due to the use of Invar ink manifolds, which are costly and less suitable for high-volume manufacturing.
Innovation Solution
A cost-effective inkjet printhead design featuring a moldable manifold with a stiffener plate and a common PCB for power and data distribution, allowing for redundant printing in multiple colors with a compact print zone, suitable for modular pagewide arrangements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Invar ink manifolds are used to provide stiffness for long printheads, then structural rigidity is improved, but manufacturing cost increases and high-volume manufacturing capability deteriorates
Solution Approach 1:
The patent employs a composite structure combining an LCP polymer manifold with a separate stiffener plate. The LCP manifold provides moldability for high-volume manufacturing, while the stiffener plate (made from rigid materials like metal or rigid polymer) provides the necessary structural rigidity. This composite approach allows cost-effective mass production through molded polymer manifolds while achieving the required stiffness for long printhead applications.
Solution Approach 2:
The ink manifold system is segmented into two functional components: the LCP polymer manifold body that is moldable and suitable for high-volume manufacturing, and a separate stiffener plate that provides structural reinforcement. This segmentation allows each component to be optimized independently - the manifold for manufacturability and the stiffener for rigidity - resolving the contradiction between ease of manufacture and structural strength.
2Adaptability or versatility
If four monochrome print bars are stacked for full-color printing, then color printing capability is achieved, but print zone length increases causing alignment challenges
Solution Approach 1:
The patent transitions from a vertical stacking arrangement (along the media feed direction) to a lateral arrangement where multiple print chips are positioned side-by-side along the width of the printhead. This dimensional change allows full-color printing capability to be achieved without increasing the print zone length in the media feed direction, thereby eliminating alignment challenges while maintaining color printing versatility.
Solution Approach 2:
Multiple print chips (e.g., CMYK print chips) are merged into a single integrated printhead assembly with a common LCP manifold and shared stiffener plate. This consolidation achieves full-color printing capability within a compact footprint, eliminating the need for separate monochrome print bars stacked along the media feed path, thus reducing print zone length while maintaining color printing versatility.
3Reliability
If multiple rows of print chips are mounted on the manifold, then full-color redundant printing is achieved, but device complexity increases
Solution Approach 1:
The LCP manifold is designed as a universal platform that can accommodate multiple rows of print chips (e.g., CMYK configurations) with redundant nozzle arrangements. The same basic manifold structure, ink supply channel layout, and stiffener plate design can be used across different printhead configurations, achieving redundant printing capability without proportionally increasing device complexity. The modular design allows the same components to serve multiple functions across different color configurations.
Data Source
AI summary
An inkjet printhead includes an elongate manifold having an upper face and a lower face, ink supply channels extending along a length of the manifold, and first and second rows of butting print chips mounted to the lower face of the manifold. A stiffener plate is fastened to the upper face of the manifold, wherein the manifold is comprised of a moldable first material and the stiffener plate has a higher degree of stiffness than the manifold. The stiffener plate is formed of a second material different than the first material.