Automatic Nozzle Alignment in Electrostatic Jet Printing

Solution Overview

Problem

Conventional electrostatic jet printers require manual alignment of the nozzle, which is time-consuming and prone to operator error when the printer is initialized or the nozzle is replaced, limiting efficiency and accuracy in ultrafine printing processes.

Innovation Solution

A printing apparatus equipped with a camera imaging system and an automatic positioning controller that automatically aligns the nozzle by capturing images from multiple angles, using lighting to enhance image clarity, and adjusting the nozzle's position to maximize sharpness and determine absolute coordinates based on printed patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If manual alignment of the nozzle is performed by an operator, then the nozzle position can be adjusted, but the process is time-consuming and prone to operator error

Engineering Contradiction:

Improvenozzle alignment precisionVSAvoidalignment time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent replaces the manual mechanical alignment system with an automated optical-mechanical system. A camera captures images of the substrate and nozzle, and a controller automatically processes these images to determine the nozzle's precise position and adjust it accordingly, eliminating the need for manual operator intervention while improving both speed and precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system enables self-alignment by using the camera to capture images, the controller to process these images and calculate position deviations, and the driving device to automatically adjust the nozzle position based on calculated corrections, creating a self-service alignment system that operates without human intervention.

Inventive Principle:

Principle #25Self-service

2Reliability

If manual alignment of the nozzle is performed by an operator, then the nozzle position can be adjusted, but operator technical skill and dexterity affect alignment accuracy

Engineering Contradiction:

Improvealignment reliabilityVSAvoidalignment operation complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces the manual mechanical alignment system with an automated optical-mechanical system. A camera captures images of the substrate and nozzle, and a controller automatically processes these images to determine the nozzle's precise position and adjust it accordingly, eliminating the need for manual operator intervention while improving both speed and precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates a visual copy of the physical alignment process by capturing images with a camera. These images serve as digital representations that the controller processes to determine position deviations and calculate correction amounts, replacing the operator's visual assessment and manual adjustment with automated image-based measurement and control.

Inventive Principle:

Principle #26Copying

3Adaptability or versatility

If the nozzle is replaced during printing operations, then different line-width printing can be performed, but re-alignment is required which reduces productivity

Engineering Contradiction:

Improveprinting capability versatilityVSAvoidprinting productivity

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The system performs preliminary alignment by capturing images of the substrate and nozzle before printing operations begin. The controller processes these images to determine the nozzle's precise position and pre-adjusts it to the optimal printing position, so that when nozzle replacement occurs, the new nozzle can be quickly aligned using the same automated process without disrupting the printing workflow.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces the manual mechanical alignment system with an automated optical-mechanical system. A camera captures images of the substrate and nozzle, and a controller automatically processes these images to determine the nozzle's precise position and adjust it accordingly, eliminating the need for manual operator intervention while improving both speed and precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10807358B2Printing apparatus

Publication Date: 2020.10.20 ENJET CO LTD

AI summary

Disclosed is a printing apparatus. In an exemplary embodiment, the printing apparatus includes a nozzle for ejecting ink, a driving device for moving the nozzle, an imaging device for capturing an image displaying an ink printing process, and an automatic positioning controller for automatically setting a position of the nozzle based on the image captured by the imaging device while moving the nozzle by means of the driving device.