Printhead Nozzle Mapping Using Imager-Based Ejection Control
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Solution Overview
Problem
Inkjet printing systems face challenges in achieving high precision positioning of dispensing nozzles and substrates due to tiny imperfections and variations in dimensions, substrate mis-positioning, and imprecision in translation speed, making it difficult to control print material droplets accurately.
Innovation Solution
A printing system utilizing a line scan imager to capture images of marks on a printhead assembly, determining nozzle positions, and mapping them to a frame of reference, enabling precise control of print material ejection.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional inkjet printing systems are used without imager-based positioning, then the system structure is simpler and operation is easier, but manufacturing precision and positioning accuracy deteriorate due to tiny imperfections and variations in dimensions
Solution Approach 1:
The system performs preliminary imaging of the printhead assembly to capture the actual positions of dispensing nozzles before printing begins. This pre-positioning data is used to create a mapping that compensates for manufacturing variations, allowing the system to achieve high precision without requiring perfectly manufactured components.
Solution Approach 2:
The imager provides feedback about the actual positions of dispensing nozzles and marks on the printhead assembly. This feedback is used to update the mapping between printhead coordinates and substrate coordinates, enabling real-time compensation for positioning errors and improving overall printing precision.
2Manufacturing precision
If high precision positioning is pursued through traditional mechanical methods, then positioning accuracy may improve slightly, but device complexity and cost increase significantly
Solution Approach 1:
The patent replaces complex mechanical positioning systems with an optical imaging system. Instead of using precision mechanical stages and complex actuation mechanisms to achieve sub-pixel positioning, the system uses an imager to optically detect the positions of marks and nozzles, then uses software-based coordinate mapping to achieve the required precision.
Solution Approach 2:
The system introduces marks as intermediary reference objects on the substrate and printhead assembly. These marks serve as mediators that enable precise positioning through optical detection and coordinate transformation, avoiding the need for direct mechanical positioning of the nozzles and substrate.
3Manufacturing precision
If imager-based positioning is implemented, then printing accuracy improves significantly, but device complexity and initial cost increase
Solution Approach 1:
The system creates a digital copy (image) of the printhead assembly and substrate with marks, then processes this copy through coordinate mapping algorithms. This allows the system to work with idealized digital representations rather than imperfect physical components, achieving high precision through information processing rather than mechanical precision.
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
Enhances printing accuracy by accurately positioning dispensing nozzles and substrates, allowing for precise placement of microscopic droplets, thereby improving the quality of printed products.
Implementation Method 1
The imager is movable relative to the printhead assembly and oriented in a direction opposite to the ejection direction for capturing at least one image including the plurality of marks indicating positions of the plurality of dispensing nozzles
Implementation Method 2
A piezoelectric material is arranged adjacent to a print material reservoir. Applying a voltage to the piezoelectric material causes it to deform in a way that applies a compressive force to the print material reservoir
Data Source
AI summary
A printing system includes a substrate support, a printhead assembly positioned facing the substrate support, and an imager. The printhead assembly includes a plurality of dispensing nozzles extending in an ejection direction towards the substrate support and a plurality of marks. The imager is movable relative to the printhead assembly and oriented in a direction opposite to the ejection direction for capturing at least one image including the plurality of marks indicating positions of the plurality of dispensing nozzles in the printhead assembly.