Registration Device Wire Gap Control for Wide Print Nozzle Arrays
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Solution Overview
Problem
Conventional top registration devices in mail processing systems struggle to maintain the necessary gap between wide print nozzle arrays and variable thickness media, leading to poor print quality, ink smearing, and potential damage to print nozzles, especially when handling media with inserts that cause surface distortions.
Innovation Solution
A thin wire is strategically placed across the print nozzle openings in the registration plate, supported by guides and adjustable tensioning devices, to maintain the optimal gap between the mail piece surface and print nozzles, preventing protrusion and ink contact, while minimizing ink buildup and ensuring accurate ink placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of moving object
If wide print nozzle arrays are used to increase printing width, then printing coverage is improved, but maintaining consistent gap distance becomes difficult due to variable thickness media
Solution Approach 1:
A thin wire is introduced as an intermediary element between the print nozzle array and the media. The wire spans across the printing width and makes contact with the media surface, serving as a mediator that maintains the critical gap distance. The wire is positioned at the correct distance from the nozzles and transmits this spacing information to the media surface, ensuring consistent gap maintenance even with variable thickness media.
Solution Approach 2:
The patent employs a thin wire (flexible element) that can adapt to variations in media thickness while maintaining the required gap distance. This thin flexible element conforms to the media surface profile, allowing it to maintain consistent spacing across the wide printing area despite variations in media thickness or surface irregularities.
2Area of moving object
If registration plate openings are enlarged to accommodate wide nozzle arrays, then printing width is improved, but media support is reduced leading to surface profile variations
Solution Approach 1:
The thin wire acts as an intermediary support element that spans across the enlarged registration plate openings. While the openings are large enough to accommodate wide nozzle arrays, the wire provides continuous support across the media surface, preventing excessive surface profile variations and maintaining stability where the media would otherwise be unsupported.
3Area of moving object
If conventional registration plates are used with large openings, then wide format printing is enabled, but ink smearing and nozzle damage occur due to media contact
Solution Approach 1:
Instead of having the rigid registration plate contact the media directly (which causes smearing when media protrudes), the patent uses a thin wire that copies or replicates the essential function of the registration plate - maintaining gap distance - without the harmful rigid contact. The wire is flexible and thin, so when media contacts it, the deformation is minimal and does not cause ink smearing or damage to the nozzles.
4Measurement precision
If gap distance is reduced to improve print resolution, then dot placement accuracy is improved, but print head scuffing increases
Solution Approach 1:
The thin wire serves as an intermediary that maintains the critical gap distance between the nozzles and media. By providing this intermediate support structure, the system can maintain the optimal gap distance for both print resolution and print head protection. The wire prevents the media from being pushed too close to the nozzles during transport or jam conditions, thereby preventing scuffing while maintaining the gap needed for accurate dot placement.
Data Source
AI summary
A registration device for a mail processing system having wide print nozzle arrays that reduces problems associated with printing on variable thickness media. A thin wire, held by guides, is strung across the print nozzle openings in the registration plate to support and guide the top (print) surface of a mail piece and to prevent the mail piece from protruding into the openings. The guides are positioned such that the wire passes between zones where there are no print nozzles located. A tensioning device is provided to adjust the tension of the wire to ensure the wire maintains its position within the openings. The wire acts as a guide to maintain the optimal gap between the mail piece top surface and the print nozzles.