Inkjet Printhead Thread Guide for Precise Nozzle Alignment
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Solution Overview
Problem
Sewing and embroidering machines with inkjet printheads face imprecise thread alignment due to tolerances in pulley positioning, leading to non-uniform thread coloring and decreased product quality.
Innovation Solution
An additional guide element is integrated with the printhead to precisely align the thread with the nozzles, reducing misalignment by defining the thread's position in multiple directions relative to the nozzles, and optionally using a movable guide element that can be adjusted to achieve optimal alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the thread is guided by first and second pulleys to position it relative to the nozzles, then the threading process is simplified, but misalignment of the thread with respect to the nozzles occurs due to tolerance accumulation
Solution Approach 1:
A guide element is introduced as an intermediary component between the pulleys and the nozzles. This guide element directly defines the position of the thread in front of the nozzles, acting as a mediator that eliminates the need for long thread paths through multiple pulleys. The guide element is provided on the printhead and defines the thread position both in a direction parallel to the printhead plate and in a direction perpendicular to it, thereby achieving precise alignment while maintaining ease of threading.
2Length of stationary object
If the distance between the first and second pulley is increased to accommodate machine design, then the printhead can be positioned appropriately, but the misalignment error increases proportionally
Solution Approach 1:
The function of defining thread position relative to nozzles is extracted from the pulley system and transferred to a guide element integrated with the printhead. By taking out the alignment-defining function from the distant pulley system, the invention eliminates the proportional relationship between pulley distance and alignment error. The guide element provides local, precise thread positioning independent of the overall machine layout and pulley distances.
3Adaptability or versatility
If multiple pulleys are used to guide the thread, then the thread can be routed through the printing and drying stations, but tolerance accumulation in pulley positioning causes non-uniform thread coloring
Solution Approach 1:
The guide element merges multiple positioning functions into a single integrated component on the printhead. It simultaneously defines the thread position in both the parallel direction (lateral alignment) and the perpendicular direction (distance from nozzles), combining what would otherwise require multiple separate positioning elements. This merging eliminates tolerance accumulation while maintaining the thread's ability to be routed through the printing and drying stations.
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
The guide element significantly reduces thread misalignment to less than ±0.13 mm, ensuring precise and efficient coloring of the thread, thereby enhancing the quality of the final product.
Implementation Method 1
a guide element, provided on said support structure, for guiding said thread in a position facing said nozzles. Preferably, said guide element defines the position of said thread in a first direction, substantially parallel to a plate-like element in which said nozzles are made and substantially perpendicular to a direction in which said thread is aligned with said nozzles, and in a second direction, substantially perpendicular to said plate-like element
Implementation Method 2
a plurality of firing cells included in said support structure, each firing cell being adapted to eject ink through a respective nozzle for coloring a thread
Data Source
AI summary
An inkjet printhead, in particular for sewing/embroidering machines, includes a support structure; a plurality of firing cells included in the support structure, each firing cell being adapted to eject ink through a respective nozzle for coloring a thread to be used in a sewing/embroidering machine; a guide element, provided on the support structure, for guiding the thread in a position facing said nozzles. Also disclosed are a sewing/embroidering machine including the printhead and a method for making the printhead.