Removable Jetting Module Printhead Assembly Alignment
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Solution Overview
Problem
In high-speed inkjet printing, achieving consistent alignment and replacement of printheads across wider print widths is challenging due to limitations in existing alignment systems and shutter mechanisms, which result in stitching variations and increased manufacturing costs.
Innovation Solution
A modular inkjet printhead assembly with a central rail system and repositionable shutter mechanism allows for easy removal and replacement of jetting modules, reducing nozzle array spacing and enabling wider print widths with improved alignment and maintenance capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed alignment baseplate structure is used to align multiple printheads, then alignment consistency is improved, but manufacturing cost increases significantly as print width increases
Solution Approach 1:
The alignment baseplate is divided into multiple independent kinematic alignment features, each associated with a specific printhead position. This segmentation allows the baseplate to accommodate wider print widths by adding modular alignment features without redesigning the entire structure, thus controlling manufacturing costs while maintaining alignment precision.
Solution Approach 2:
The kinematic alignment features are designed to be universally applicable across different printhead positions and configurations. The same basic alignment mechanism can be reused for various printhead arrangements, reducing manufacturing complexity and cost while providing consistent alignment performance.
2Manufacturing precision
If the spacing between nozzle arrays in two rows of printheads is reduced to minimize stitching variation, then stitching quality is improved, but device complexity increases due to tighter tolerances and more compact arrangement
Solution Approach 1:
The kinematic alignment features provide dynamic adjustment capability, allowing the printheads to be positioned with high precision relative to each other. This dynamic positioning system enables reduced spacing between nozzle arrays while maintaining alignment tolerances, thereby improving stitching quality without proportionally increasing device complexity.
3Object-affected harmful factors
If traditional shutter mechanisms are used to seal printhead outlets during maintenance, then ink leakage is prevented, but the shutter mechanism limits spacing between printhead rows and complicates maintenance operations
Solution Approach 1:
The shutter mechanism is extracted from the printhead assembly and implemented as a separate, removable component. This allows the shutter to be independently positioned and operated during maintenance procedures, eliminating the constraint on printhead row spacing and simplifying maintenance operations while still preventing ink leakage when needed.
Data Source
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AI summary
An inkjet printhead assembly includes a rail assembly and a removable jetting module. The rail assembly includes a beam and a rod attached to the beam. A printhead module includes the jetting module and a mounting assembly. The jetting module includes an array of nozzles, a first alignment tab having a first alignment datum and a second alignment datum, a second alignment tab having a third alignment datum and a fourth alignment datum, a rotational alignment feature including a fifth alignment datum, and a cross-track alignment feature including a sixth alignment datum. The mounting assembly includes a similar set of alignment features. Portions of the alignment tabs of the jetting module and the mounting assembly are adapted to fit within corresponding notches in the beam and engage with the rod. A jetting module clamping mechanism applies a force to the jetting module causing it to engage with the rail assembly.