Movable Inkjet Print Heads Dynamic Nozzle Compensation
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Solution Overview
Problem
Existing drop-on-demand (DOD) inkjet printing systems require frequent maintenance due to nozzle defects, leading to production slowdowns and increased costs, as they typically need multiple passes over the same area to compensate for defective nozzles, which can result in poorer print quality and higher equipment costs.
Innovation Solution
A DOD printing system with movable print units that can dynamically change their positions and roles during printing, allowing for continuous high-speed printing without frequent maintenance, where idle units can be moved for maintenance while active units compensate for defective nozzles, and the system adjusts nozzle positions to ensure even distribution and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple passes are used to compensate for defective nozzles, then print quality is maintained, but printing speed decreases and productivity is reduced
Solution Approach 1:
The patent implements movable print heads that can dynamically change positions during the printing process. When a defective nozzle is detected, the system dynamically adjusts by moving other print heads to compensate, eliminating the need for multiple passes and maintaining high printing speed while preserving print quality
Solution Approach 2:
The system changes the operational parameters by allowing print heads to move to different positions and roles during printing. This dynamic reconfiguration enables compensation for defective nozzles without requiring repeated passes over the same area, thus maintaining both quality and productivity
2Reliability
If frequent maintenance is performed to repair nozzle defects, then reliability is improved, but productivity decreases due to production slowdowns
Solution Approach 1:
The system performs preliminary detection of nozzle defects and proactively compensates by repositioning functional print heads before quality degradation occurs. This preventive approach maintains reliability without requiring frequent maintenance stops, thus preserving productivity
Solution Approach 2:
The printing system performs self-diagnosis and self-compensation by detecting defective nozzles and automatically redistributing printing tasks to functional nozzles through dynamic head movement. This self-service capability maintains reliability without external maintenance intervention, keeping productivity high
3Device complexity
If static jetting arrays are used, then device complexity is reduced, but the system cannot compensate for defective nozzles without multiple passes
Solution Approach 1:
The patent transitions from static to dynamic print head positioning. The movable print heads can change positions during printing to compensate for defective nozzles, enabling quality maintenance without multiple passes while adding only minimal complexity through movement mechanisms
Data Source
AI summary
Embodiments of the invention are directed to a deposition printing system which includes two or more print units capable of moving with respect to each other during printing, each of the print units having one or more print heads together forming a head arrangement; and a controller to control movement of the print units to dynamically change the head arrangement during the printing.