Variable Thickness Print Media Ink Jet Printing Distance Control
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Solution Overview
Problem
Ink jet printing technology requires a narrow depth of field, making it challenging to maintain proper distance between the print head and varying thickness mailpieces, resulting in poor image quality when the thickness exceeds a specified range.
Innovation Solution
A method and apparatus that determine the thickness of the mailpiece in real-time, adjusting the position of the print head or the transport mechanism to maintain a specified distance range between the print head and the mailpiece surface, ensuring high-quality printing across varying thicknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If ink jet printing technology is used to print on mailpieces, then printing capability is provided, but maintaining proper distance between print head and varying thickness mailpieces becomes difficult resulting in poor image quality
Solution Approach 1:
The system measures the thickness of each mailpiece before it reaches the printing station and pre-positions the print head or transport mechanism to the appropriate height. This preliminary measurement and positioning action ensures that when printing occurs, the mailpiece is already at the optimal distance from the print head, eliminating focus issues and ensuring high image quality across varying thicknesses.
Solution Approach 2:
The system implements dynamic adjustment of the print head or transport mechanism height based on real-time mailpiece thickness measurements. Rather than using a fixed positioning system, the apparatus continuously adapts its position to match the varying thickness of each mailpiece, maintaining the narrow depth of field requirement for high-quality printing across the full range of mailpiece thicknesses.
2Manufacturing precision
If the distance between print head and mailpiece surface is maintained within a narrow range, then acceptable image quality is achieved, but the system cannot accommodate variable thickness mailpieces
Solution Approach 1:
The system incorporates a feedback mechanism where the thickness of each mailpiece is measured and this information is used to adjust the print head or transport mechanism position. The measured thickness provides feedback that drives the positioning adjustment, ensuring that the distance between the print head and mailpiece surface remains within the narrow required range regardless of the mailpiece thickness variation.
Solution Approach 2:
The system changes the positional parameter (height) of the print head or transport mechanism based on the measured thickness parameter of the mailpiece. By dynamically adjusting the position parameter in response to thickness variations, the system maintains the optimal printing distance across the full range of mailpiece thicknesses from approximately 0.06 inches to 2 inches.
3Productivity
If mailpieces are transported through the printing station, then printing operation is enabled, but thickness measurement and position adjustment add system complexity
Solution Approach 1:
The system combines the thickness measurement function and the position adjustment mechanism into an integrated printing station. The measurement device, positioning mechanism, and printing components work as a unified system, where thickness measurement and position adjustment are seamlessly incorporated into the existing mailpiece transport and printing workflow, minimizing additional complexity while enabling high-quality printing on variable thickness media.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Ensures high-quality printing on mailpieces of varying thickness by maintaining the optimal distance between the print head and the mailpiece surface, enhancing image resolution and quality.
Implementation Method 1
determining a thickness of the print medium while the print medium is being transported toward a printing station
Implementation Method 2
It is the activation of the ejection elements that causes drops of ink to be expelled from the nozzles toward the print medium to collectively form a print image
Data Source
AI summary
A method for printing information on a print medium, such as a mailpiece, that includes determining a thickness of the medium while it is being transported toward a print head, such as an ink jet print head, causing the distance between the top surface of the medium the print head when the medium is located below the print head to be within a specified range based on the determined thickness, and printing the information on the print medium. Also, an apparatus includes a printing station having a print head, a transport mechanism for transporting the medium toward the printing station, and a thickness measuring mechanism. The apparatus is structured to cause the distance between the top surface of the medium and a portion of the print head when the medium is located below the print head to be within a specified distance range based on the thickness of the medium.