Full-Width Inkjet Print Head Array with Pivoting Resolution Control
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Solution Overview
Problem
Conventional wide format inkjet printers face challenges in achieving high resolution without sacrificing print speed, as they either require scanning carriage movements or are costly and unreliable due to custom print heads or fragile silicon ink chips.
Innovation Solution
A printer design featuring a support structure with an array of conventional piezoelectric inkjet print heads spanning the substrate width, allowing for continuous resolution across the entire width without scanning, and the ability to rotate print heads to achieve higher resolutions through multiple passes and offset positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional scanning wide format printer uses a carriage that scans back and forth to achieve high resolution, then print resolution is improved, but print speed deteriorates
Solution Approach 1:
The patent divides the full-width print head into multiple separate print head modules arranged in parallel. Each module can be independently manufactured using conventional technologies and then assembled together to form a complete full-width print head, resolving the contradiction between achieving high resolution and maintaining print speed.
Solution Approach 2:
The patent transitions from a single-axis scanning approach to a multi-dimensional parallel processing approach by arranging multiple print head modules side-by-side across the full width of the substrate, enabling simultaneous printing across the entire width without scanning movements.
2Manufacturing precision
If a full width inkjet printer uses arrays of silicon ink chips to achieve continuous resolution, then print resolution is improved, but reliability deteriorates due to fragility
Solution Approach 1:
The patent employs conventional piezoelectric print head modules that are more robust and easier to replace than silicon ink chips. These modules can be manufactured using established processes and are less fragile, improving reliability while maintaining the ability to achieve continuous resolution through proper module arrangement and spacing.
3Manufacturing precision
If a full width inkjet printer uses custom-designed print heads to eliminate gaps and achieve continuous resolution, then print resolution is improved, but manufacturing cost deteriorates
Solution Approach 1:
The patent segments the full-width print head into multiple standard modules that can be manufactured separately using conventional processes and then assembled. This approach avoids the high cost of designing and manufacturing a completely custom monolithic print head while achieving continuous resolution through proper module placement and overlap.
Solution Approach 2:
The patent designs the print head modules to be universal components that can be used in different configurations and applications. The modules are based on conventional, well-established technologies that benefit from economies of scale, reducing manufacturing costs compared to custom solutions.
4Ease of manufacture
If conventional piezoelectric print heads are used in a full width array, then manufacturing cost is reduced, but gaps between print heads create discontinuous resolution
Solution Approach 1:
The patent addresses the gap issue by arranging multiple print head modules in parallel across the full width, creating continuity in the width dimension through proper spacing and overlap design, while maintaining the use of cost-effective conventional piezoelectric technology.
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
Enables high-resolution printing at high speeds with conventional piezoelectric inkjet technology, maintaining print quality and reliability while avoiding the costs and fragility issues of custom or alternative print head solutions.
Implementation Method 1
a piezoelectric vibrator applies pressure to an ink reservoir of a print head to force ink through nozzles
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A printer comprising: a conveyor (14) defining an X direction (W) and a Y direction (L) perpendicular to the X direction, the conveyor configured to receive a substrate (20) of maximum width in the X direction and to move the substrate linearly in the Y direction; a first array (34e) of multiple inkjet print heads distributed along a length of the first array; where the print heads have a prescribed native resolution and a prescribed dot pitch; one support (16e), spanning the conveyor in the X direction, where the first array is pivotably mounted (40) at its midpoint to the support, where the first array is pivotable about an axis perpendicular to the X and Y directions, and where during printing the array is pivoted sufficient to reduce and compress a width of printing applied in the X direction and causing printing to occur in greater resolution than said native resolution.