Inkjet Printhead PCB Layout for Compact Dual-Row Print Chips
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing modular inkjet printing systems face challenges in minimizing print zone length, require efficient ink and power supply arrangements, and are costly for OEMs, and are not cost-effective or versatile for high-volume manufacturing.
Innovation Solution
A cost-effective inkjet printhead with an elongate manifold and dual rows of print chips, each receiving ink from opposite sides, and a common PCB distributing power and data, with a stiffener plate for rigidity, allowing for compact and efficient modular arrangement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If four monochrome print bars are stacked along the media feed path to achieve full-color printing, then full-color printing capability is achieved, but the overall span of the print zone becomes very long (500-1000 mm)
Solution Approach 1:
The patent transitions from a linear arrangement of four separate print bars stacked along the media feed path to a two-dimensional planar arrangement where four print chips are mounted side-by-side on a single printhead body. This dimensional reorganization reduces the print zone span from 500-1000 mm to a compact width while maintaining full-color CMYK printing capability through the lateral arrangement of cyan, magenta, yellow, and black print chips.
Solution Approach 2:
The patent combines four separate monochrome printheads into a single integrated full-color printhead unit. By merging the four print bars into one compact structure with a unified manifold and PCB assembly, the system achieves full-color printing without requiring the media to traverse a long distance through multiple stacked print zones, thereby reducing the overall print zone span.
2Stability of the object's composition
If Invar ink manifolds are used to provide rigidity for long printheads, then structural stability is improved, but manufacturing cost increases and high-volume manufacturing becomes less suitable
Solution Approach 1:
The patent changes the material parameter from Invar (a nickel-iron alloy) to LCP (liquid crystal polymer). This material substitution maintains sufficient structural rigidity for the compact printhead design while enabling cost-effective high-volume manufacturing through injection molding processes, directly addressing the contradiction between structural stability and manufacturing scalability.
Solution Approach 2:
The patent adopts LCP manifolds that can be manufactured as disposable or single-use components through injection molding. This approach reduces the cost per unit and enables high-volume production, accepting that the manifold may have limited reuse potential compared to expensive Invar manifolds, thereby prioritizing manufacturing efficiency over component longevity.
3Length of moving object
If a compact single printhead with four print chips is used to reduce print zone span, then integration into existing offset media feed systems becomes easier, but efficient ink supply to all four print chips becomes more challenging
Solution Approach 1:
The patent segments the ink supply system into four separate ink supply channels within the manifold, each dedicated to a specific print chip (cyan, magenta, yellow, black). This segmentation allows independent ink delivery to each print chip while maintaining a compact unified structure, resolving the contradiction between compactness and ink supply efficiency.
Solution Approach 2:
The patent introduces a manifold as an intermediary component that mediates between the ink supply source and the four print chips. The manifold contains internal channels that distribute ink to each print chip, acting as a compact distribution network that simplifies the overall ink supply arrangement while enabling efficient delivery to all four print chips in the lateral arrangement.
4Reliability
If redundant nozzle rows are implemented in each print chip for high-quality printing, then printing quality and reliability are improved, but the number of print chips and overall system complexity increases
Solution Approach 1:
The patent implements multi-functionality within each print chip by incorporating two nozzle rows (active and redundant) into a single print chip design. This allows each print chip to serve both primary printing and backup functions, providing redundancy and high-quality printing capability without requiring additional separate print chips, thereby reducing overall system complexity.
Data Source
AI summary
An inkjet printhead includes: an elongate manifold having through-holes defined through a thickness of the manifold and ink supply channels extending along a length of the manifold. First and second rows of butting print chips are mounted to a lower face of the manifold and receive ink from the ink supply channels. A first PCB is mounted to lower face of the manifold between the first and second rows of print chips. The first PCB receives power and data via the through-holes from a second PCB and the first PCB distributes the power and data to both the first and second rows of butting print chips at either side thereof.