Kinematic Printhead Alignment Assembly
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Solution Overview
Problem
Conventional techniques for aligning components in inkjet printheads are inefficient due to high assembly times, sensitivity to heat and humidity, and increased manufacturing complexity, particularly in achieving precise multi-dimensional tolerances for locating elements, which hinders field replaceability and increases costs.
Innovation Solution
The use of a kinematic alignment system with a first member, a second member, and a plurality of locating elements, where the second member includes through holes and a third member acts as a spacer, forming pockets for interference fits that allow precise positioning with reduced machining errors and costs, utilizing kinematic mounts like the 2-2-2 or 3-2-1 configurations for reproducible alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional adhesive assembly techniques are used to align printhead components, then assembly is simplified, but assembly time increases significantly due to curing requirements
Solution Approach 1:
The patent replaces adhesive bonding with a mechanical alignment system consisting of locating elements (spherical or cylindrical) that fit into precision-machined recesses in the printhead components. This mechanical system provides immediate alignment without requiring chemical curing time, thereby resolving the contradiction between assembly simplicity and assembly time.
2Strength
If epoxy adhesive is used for assembly, then components are secured together, but sensitivity to heat and humidity increases
Solution Approach 1:
The patent eliminates epoxy adhesive and uses purely mechanical means (locating elements in precision recesses) to secure and align components. This mechanical system is not sensitive to heat and humidity conditions, thereby resolving the contradiction between component bonding strength and environmental sensitivity.
3Manufacturing precision
If precision ground balls or cylindrical pins are used as locating elements, then alignment accuracy is achieved, but manufacturing complexity and costs increase due to tight tolerance requirements
Solution Approach 1:
The patent uses spherical locating elements that provide alignment in multiple degrees of freedom simultaneously. The spherical shape inherently compensates for minor manufacturing variations and provides robust alignment without requiring extremely tight tolerances on all surfaces, thereby achieving high alignment accuracy with reduced manufacturing complexity compared to precision ground balls or cylindrical pins.
4Manufacturing precision
If dedicated assembly fixtures are used in the factory, then alignment precision is maintained, but field replaceability of components is hindered
Solution Approach 1:
The patent incorporates locating elements and precision recesses directly into the printhead components themselves, creating self-aligning features that do not require external assembly fixtures. This allows components to be precisely aligned and reassembled in the field without specialized equipment, thereby resolving the contradiction between alignment precision and field replaceability.
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
This approach enables precise, reproducible alignment of printhead components with reduced manufacturing complexity and costs, enhancing field replaceability and maintaining high precision across large printing areas, while minimizing deformation and wear.
Implementation Method 1
The plurality of locating elements include a first locating element positioned with an interference fit in the first pocket and a second locating element positioned with an interference fit in the second pocket
Implementation Method 2
When the two components are mated, elastic deformations are generated in each of the components which generate frictional forces that secure the two components together
Data Source
AI summary
An alignment component includes first and second members and locating elements. The first member includes at least one surface. The second member includes first and second through holes positioned relative to each other. The second member is affixed with the first member such that first and second pockets are formed. The first and second pockets have a wall corresponding to a wall of the first or second through holes. The first and second pockets have a base corresponding to a surface of the one or more surfaces of the first member. The locating elements include first and second locating elements positioned with an interference fit in the first and second pockets. A wall and a base of the first and second pockets define first and second components of position, respectively, of the first locating element relative to the second locating element.