Modular Printhead Assembly for Web Printing Maintenance
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Solution Overview
Problem
Existing high-speed inkjet web printers face challenges in performing printhead maintenance without breaking the media web, are costly, and struggle with scalability for wider media widths, particularly when integrated into existing offset printing presses.
Innovation Solution
A modular printer design featuring transversely extending printheads with overlapping maintenance sleds that allow for maintenance without breaking the media web, enabling scalability to wider widths and integration with existing web feed mechanisms, with identical printhead cartridges for cost efficiency and consistent print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a single multi-color pagewidth printhead with integrated web feed mechanism is used, then maintenance can be performed without breaking the media web, but the device complexity and cost increase
Solution Approach 1:
The printer is divided into separate functional modules: a media feed mechanism (can be from an offset press) and a printhead module. This segmentation allows the printhead to be maintained independently without requiring an integrated complex web feed system, thereby reducing overall device complexity while maintaining maintenance capability.
Solution Approach 2:
The media feed mechanism is designed to be universal, capable of working with multiple printhead types and configurations. This universality allows the simple web feed to serve various printing functions without requiring complex integration specific to each printhead design.
2Ease of operation
If a scissor lift mechanism with multiple monochrome printheads is used, then printhead maintenance can be performed without breaking the media web, but the device cost and complexity increase
Solution Approach 1:
The printing function is segmented from the maintenance function. The printhead can be easily removed and replaced independently from the media feed system, eliminating the need for complex scissor lift mechanisms while still enabling maintenance without breaking the media web.
Solution Approach 2:
The printhead mounting is designed to be dynamically adjustable and easily replaceable, allowing quick maintenance operations without requiring complex mechanical lift systems. The simplicity of the mounting mechanism enables fast printhead changes while maintaining media web integrity.
3Adaptability or versatility
If staggered overlapping printheads with rotatable maintenance carousels are used, then each printhead can be maintained individually, but the media web must be broken for maintenance
Solution Approach 1:
The printhead is segmented as a separate, easily removable module that can be maintained independently. This segmentation allows the printhead to be serviced without interrupting the media web feed, as the maintenance operations do not require breaking the web.
Solution Approach 2:
The printhead is extracted as a separate maintenance unit that can be serviced independently from the media feed system. This extraction allows maintenance to be performed on the printhead without affecting the continuity of the media web, eliminating the need to break the web for maintenance.
4Ease of manufacture
If existing offset printing press web feed mechanisms are utilized, then integration is simplified, but scalability to wider media widths is limited
Solution Approach 1:
The printhead module is designed with universal mounting capabilities that can accommodate different media widths. The printhead can be positioned at various locations along the media width, allowing the same basic mechanism to scale from narrow to wide format printing while maintaining compatibility with existing offset press web feeds.
Solution Approach 2:
The solution adds dimensional flexibility by allowing the printhead to operate in multiple positions along the media width dimension. This enables scalability to wider media widths without changing the fundamental web feed mechanism, as the printhead can be repositioned laterally to match different media widths.
Data Source
AI summary
A print bar assembly includes: a mounting frame having a pair of opposite first and second sidewalls extending parallel to a media feed direction, the first sidewall having an upwardly extending first guide slot defined between opposite first bearing surfaces; a print bar carriage slidably received within the mounting frame and an actuation mechanism operatively connected to the print bar carriage for lifting and lowering the print bar carriage relative to the mounting frame. The print bar carriage includes a chassis, a printhead and a pair of first bearings rotatably received in the first guide slot. During sliding movement of the print bar carriage, the pair of first bearings travel within the first guide slot and bear against the first bearing surfaces to constrain rotational movement of the print bar carriage.