Inkjet Printhead Module with Interleaved Projections for Compact Print Zone
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Solution Overview
Problem
Existing modular inkjet printing systems have long print zones for full-color printing, which pose challenges in alignment, dot-on-dot placement, and integration with existing offset media feed systems, particularly due to limited space and high reconfiguration costs.
Innovation Solution
A modular inkjet printhead design featuring a monolithic substrate with multiple rows of print chips, where each row receives power and data through longitudinal slots, and is supplied with ink through parallel channels, allowing for efficient power and ink distribution and minimizing the print zone length.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple monochrome print bars are stacked to provide full-color printing with redundancy, then printing quality and speed are improved, but the overall print zone length increases
Solution Approach 1:
The patent transitions from a longitudinal stacking arrangement (where print bars are arranged along the media feed path) to a transverse arrangement where multiple printhead modules are positioned side-by-side across the media feed path. This dimensional change allows multiple color channels to be printed simultaneously within a compact footprint, reducing the print zone length while maintaining full-color capability and redundancy.
Solution Approach 2:
The printhead is divided into multiple independent printhead modules, each containing a subset of print chips for different color channels. These modules can be independently controlled and positioned, allowing them to be arranged in a compact configuration that minimizes the overall print zone length while providing redundant printing capability through the modular architecture.
2Length of moving object
If print bars are arranged to minimize inter-print bar separation, then print zone length is reduced, but alignment and dot-on-dot placement become more challenging
Solution Approach 1:
A common substrate is introduced as an intermediary structure that mechanically supports and precisely positions multiple printhead modules. The substrate provides a rigid foundation with built-in alignment features that ensure accurate positioning of print chips across different color channels, eliminating the need for complex external alignment mechanisms while maintaining tight inter-print bar separation.
Solution Approach 2:
Multiple printhead modules are integrated onto a single common substrate, merging their positioning and alignment functions into one unified structure. This integration ensures that all print chips are precisely aligned relative to each other, solving the alignment precision problem that arises when minimizing inter-print bar separation.
3Adaptability or versatility
If a long print zone is used to accommodate multiple color channels, then full-color printing with redundancy is achieved, but integration with existing offset media feed systems becomes difficult
Solution Approach 1:
The patent repositions the multi-color printing function from the longitudinal direction (along the media feed path) to the transverse direction (across the media feed path). This allows the print engine to be compact in the longitudinal direction, making it easier to integrate with existing offset media feed systems while maintaining full-color printing capability through the transverse arrangement of multiple printhead modules.
Solution Approach 2:
The modular printhead design with a common substrate serves multiple functions: it provides full-color printing capability, maintains compact dimensions for integration with existing systems, and offers redundant printing through multiple print chips per color channel. This multi-functionality makes the design particularly suitable for digital inkjet presses that need to replace traditional analogue printing plates.
Data Source
AI summary
A printhead module includes an ink manifold having longitudinal ink supply channels its length and first and second of rows of print chips mounted on a front face of the ink manifold, each of the first and second rows containing a plurality of butting print chips. A pair of first coaxial projections extend outwardly away from respective first and second opposite ends of the ink manifold, and a pair of second coaxial projections extend outwardly away from their respective first and second ends. The pair of first projections both contain part of the first row of print chips and the pair of second projections both contain part of the second row of print chips.