Liquid Ejecting Head Module Segmentation and Staggered Alignment
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Solution Overview
Problem
Existing liquid ejecting head modules face challenges in increasing nozzle density due to manufacturing costs and yield impairment, and suffer from impaired printing quality due to size increases and nozzle alignment issues, making it difficult to replace faulty heads and maintain precise nozzle alignment.
Innovation Solution
The solution involves a liquid ejecting head module with a configuration of multiple holders and head units, where each head unit has projecting and cut-off portions for overlapping alignment, allowing for linear arrangement and reduced size, along with strategically placed connectors to facilitate easy replacement and minimize size expansion, thereby enhancing manufacturing yield and printing quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple liquid ejecting heads are mounted on a single head unit to extend nozzle rows, then the nozzle row length is increased, but the head unit size increases in the second direction causing misalignment and printing quality degradation
Solution Approach 1:
The head unit is divided into multiple independent head modules, each containing a subset of liquid ejecting heads. These modules can be independently manufactured, tested, and replaced. The projecting portions and cut-off portions create modular segments that can be precisely positioned relative to each other, maintaining nozzle alignment while distributing the overall nozzle row across multiple manageable units.
Solution Approach 2:
Instead of extending the nozzle row by adding heads in the second direction (which causes misalignment), the patent uses projecting portions and cut-off portions to create overlapping arrangements where heads from adjacent head units extend the nozzle row in the first direction. This dimensional strategy allows nozzle row extension without increasing head unit size in the problematic second direction.
2Manufacturing precision
If head units are staggered to form extended nozzle rows, then the nozzle apertures can be aligned consecutively, but the head module size increases making the apparatus larger
Solution Approach 1:
The head units feature asymmetric projecting portions at one end and cut-off portions at the other end. This asymmetric design allows head units to be staggered in a specific pattern where the projecting portion of one head unit fits into the space created by the cut-off portion of the adjacent unit. This asymmetric staggering enables precise nozzle alignment while minimizing the overall head module volume compared to symmetric arrangements.
3Reliability
If a faulty liquid ejecting head needs replacement, then the head unit must be dismounted and replaced integrally, but this requires complicated disassembly and repositioning procedures
Solution Approach 1:
The head unit is segmented into independently replaceable head modules identified by projecting portions and cut-off portions. When a faulty head needs replacement, only the specific head module containing the defective head must be removed and replaced, rather than replacing the entire head unit. This segmentation dramatically simplifies the repair process while maintaining system reliability.
Solution Approach 2:
The faulty liquid ejecting head or its containing head module is extracted from the system for replacement. The projecting portions and cut-off portions are designed to facilitate this extraction by providing clear mechanical interfaces that allow individual modules to be removed without affecting other heads. This extraction principle enables selective replacement of only the necessary component.
4Length of moving object
If the head unit size is increased to accommodate more heads, then the nozzle row is extended, but the connectors and wiring become more complex and difficult to manage
Solution Approach 1:
The electrical wiring and liquid supply connections are segmented to match the modular head unit structure. Each head module with its projecting and cut-off portions has dedicated connectors and wiring that terminate at the module level. This segmentation prevents wiring complexity from increasing proportionally with nozzle row length, as each module can be independently connected and tested.
Solution Approach 2:
The projecting portions and cut-off portions serve as mechanical intermediaries that also guide and organize the wiring and liquid supply connections. These structural features provide natural pathways and mounting points for connectors, reducing wiring complexity by integrating the connection infrastructure into the modular architecture rather than adding separate complex routing systems.
Data Source
AI summary
A liquid ejection head module is disclosed. The liquid ejection head module includes first and second head units disposed in a first direction. The first and second head units have first and second rows of liquid ejecting heads that have a plurality of nozzles disposed in the first direction. The first and second rows of liquid ejecting heads are disposed in a second direction crossing the first direction. The first and second head each have a projecting portion. A connector is disposed on each of the first and second head units and each connector is disposed so that the connecting port is open at a side opposite from a liquid ejecting side.