Adjustable gloss level for compact printhead arrangement

• US 10,589,506 B2
• Filed: 10/06/2016
• Issued: 03/17/2020
• Est. Priority Date: 10/30/2015
• Status: Active Grant

• Current Assignee: Nike, Inc.
• Original Assignee: Nike, Inc.
• Inventors: Miller, Todd W.
• Primary Examiner(s): Davis, Robert B
• Application Number:
  US15/287,529
• Publication Number:
  US 20170120520A1
• Time in Patent Office: 1,258 Days
• CPC Class Codes: B29C 64/112 using individual droplets, e.g. from jetting heads
• CPC Class Codes: B29C 64/209 Heads; Nozzles
• CPC Class Codes: B29C 64/264 Arrangements for irradiation
• CPC Class Codes: B29K 2995/002 Coloured
• CPC Class Codes: B29K 2995/0022 Bright, glossy or shiny surface
• CPC Class Codes: B33Y 10/00 Processes of additive manufacturing
• CPC Class Codes: B33Y 30/00 Apparatus for additive manufacturing; Details thereof or accessories therefor
• CPC Class Codes: B33Y 70/00 Materials specially adapted for additive manufacturing
• CPC Class Codes: B41J 11/00214 using UV radiation
• CPC Class Codes: B41J 2/2114 Ejecting specialized liquids, e.g. transparent or processing liquids B41J2/211 takes precedence
• CPC Class Codes: B41J 3/407 for marking on special material

Abstract

A method and apparatus for printing 2D layers and 3D structures is disclosed. The method includes dispensing a print material from a printhead assembly onto a base and curing the print material with a curing device assembly. The spacing between the printhead assembly and the curing device assembly can be adjusted to vary gloss levels in a printed feature. The printhead assembly can include at least one row of nozzles with colored inks and at least one row of nozzles with a clear structural print material.

Claims

1. An apparatus for printing a printable feature onto a base, the apparatus comprising:

a printing surface for receiving the base;

a printhead assembly comprising a first printhead and a second printhead, wherein the first printhead comprises a first row of print nozzles, wherein the second printhead comprises a second row of print nozzles, wherein the first row of print nozzles is disposed adjacent to and parallel with the second row of print nozzles, and wherein the printhead assembly is movable along a primary axis;

a curing device assembly comprising a first housing, a first curing device, a second housing, and a second curing device, wherein the first housing and the second housing are disposed on a first side of the printhead assembly, wherein the first curing device is disposed within the first housing, wherein the first housing is independently movable relative to the printhead assembly and the second housing, and wherein the second curing device is disposed within the second housing, wherein the first housing and the first curing device are movable relative to the first printhead, the second printhead, the second housing, and the second curing device along a first axis, wherein the first axis is parallel to the primary axis and the first row of print nozzles, wherein the second housing and the second curing device are movable relative to the first printhead, the first housing, the first curing device, and the second printhead along a second axis, and wherein the second axis is parallel to the primary axis, the first axis, and the second row of print nozzles;

an actuating system comprising a primary rail, a first rail, a second rail, a primary actuating device, a first actuating device, a second actuating device, and a controller, wherein the printhead assembly is mounted on the primary rail by the primary actuating device, wherein the first housing of the curing device assembly is mounted to the first rail by the first actuating device, wherein the second housing of the curing device assembly is mounted to the second rail by the second actuating device, wherein the controller is configured to independently control the primary actuating device, the first actuating device, and the second actuating device, wherein the primary actuating device is configured to move the printhead assembly along the primary axis and relative to an upper surface of the base, wherein the first actuating device is configured to independently move the first housing and the first curing device relative to the first printhead and the second curing device along the first axis in a range between a first inward spacing and a first outward spacing, and wherein the second actuating device is configured to independently move the second housing and the second curing device relative to the second printhead and the first curing device along the second axis in a range between a second inward spacing and a second outward spacing;

wherein the first printhead is configured to dispense a first print material in a liquid state while the actuating system moves the printhead assembly and the curing device assembly;

wherein the controller and the first actuating device are configured to automatically move the first curing device along the first axis to a first separation distance relative to the first printhead;

wherein the first curing device is configured to cure the first print material while the first curing device is at the first separation distance;

wherein the second printhead is configured to dispense a second print material while the actuating system moves the printhead assembly and the curing device assembly;

wherein the controller and the second actuating device are configured to automatically move the second curing device along the second axis to a second separation distance relative to the second printhead, the second separation distance being different than the first separation distance; and

wherein the second curing device is configured to cure the second print material while the second curing device is at the second separation distance.

2. The apparatus for printing as in claim 1, wherein the first separation distance is greater than the second separation distance.

3. The apparatus for printing as in claim 1, wherein the first separation distance is less than the second separation distance.

4. The apparatus for printing as in claim 1, wherein the controller and the first actuating device are configured to automatically move the first curing device along the first axis from the first separation distance to a third separation distance relative to the first printhead;

and

wherein the controller and the first actuating device are configured to automatically move the second curing device along the second axis from the second separation distance to a fourth separation distance relative to the second printhead.

5. The apparatus for printing according to claim 1, wherein the first row of print nozzles are aligned with the second row of print nozzles to form a column of print nozzles that is perpendicular to each row of print nozzles.

6. The apparatus for printing according to claim 5, wherein a first nozzle in the first printhead and in the column of print nozzles is disposed closer to the first curing device than any remaining print nozzles in the first printhead;

and

wherein a second nozzle in the second printhead and in the column of print nozzles is disposed closer to the second curing device than any remaining print nozzles in the second printhead.

7. The apparatus for printing according to claim 1, wherein the first printhead comprises print nozzles configured to print colored print materials and wherein the second printhead comprises print nozzles configured to print clear print materials.

8. The apparatus for printing according to claim 1, wherein the printable feature is a three-dimensional structural component.

9. The apparatus for printing as in claim 1, wherein the first curing device is spaced closer to the first printhead with the first inward spacing than with the first outward spacing.

10. The apparatus for printing as in claim 9, wherein the second curing device is spaced closer to the second printhead with the second inward spacing than with the second outward spacing.

11. The apparatus for printing as in claim 10, wherein the first inward spacing corresponds with a matte finish for print material printed by the first printhead, and wherein the second inward spacing corresponds with the matte finish for print material printed by the second printhead;

and

wherein the first outward spacing corresponds with a glossy finish for print material printed by the first printhead, and wherein the second outward spacing corresponds with the glossy finish for print material printed by the second printhead.

12. The apparatus for printing as in claim 11, wherein spacing of the curing device assembly relative to the printhead assembly is configured to be adjusted automatically.

13. The apparatus for printing as in claim 12, wherein the controller automatically adjusts the spacing of the curing device assembly relative to the printhead assembly according to a target gloss level for a portion of the printable feature.

14. The apparatus for printing as in claim 1, wherein the base is an upper for an article of footwear.

15. An apparatus for printing a three-dimensional structural component onto a base, the apparatus comprising:

a printing surface for receiving the base;

a printhead assembly comprising a first printhead and a second printhead;

the first printhead comprising a first row of print nozzles and the second printhead comprising a second row of print nozzles;

the first row of print nozzles being disposed adjacent to and parallel with the second row of print nozzles;

the first row of print nozzles being aligned with the second row of print nozzles to form a column of print nozzles that is perpendicular to each row of print nozzles;

a curing device assembly disposed on a first side of the printhead assembly and comprising a first curing device aligned with the first printhead along a first axis and a second curing device aligned with the second printhead along a second axis;

an actuating system comprising a primary rail, a first rail, a second rail, a primary actuating device, a first actuating device, a second actuating device, and a controller, wherein the primary rail, the first rail, and the second rail are spaced apart from each other and are parallel to each other, wherein the printhead assembly is coupled to the primary rail by the primary actuating device, wherein the first curing device is coupled to the first rail by the first actuating device, wherein the second curing device is coupled to the second rail by the second actuating device, wherein the controller is configured to independently control the primary actuating device, the first actuating device, and the second actuating device, wherein the primary actuating device is configured to automatically and independently move the printhead assembly relative to the primary rail and relative to the printing surface and the base, wherein the first actuating device is configured to automatically and independently move the first curing device relative to the first rail and along the first axis to a first separation distance relative to the first printhead and the second curing device, and wherein the second actuating device is configured to automatically and independently move the second curing device relative to the second rail and along the second axis to a second separation distance relative to the second printhead and the first curing device, the second separation distance being different than the first separation distance;

wherein the first printhead is configured to dispense a first print material onto the base, wherein the first curing device is configured to cure the first print material, and wherein the controller is configured to move the first curing device to the first separation distance; and

wherein the second printhead is configured to dispense a second print material onto the base, wherein the second curing device is configured to cure the second print material, and wherein the controller is configured to move the second curing device to the second separation distance.

16. The apparatus for printing as in claim 15, wherein the controller and the first actuating device are further configured to position the first curing device relative to the first printhead to at least a first inward spacing and a first outward spacing along the first axis, the first separation distance being disposed between the first inward spacing and the first outward spacing;

wherein the controller and the second actuating device are further configured to position the second curing device relative to the second printhead to at least a second inward spacing and a second outward spacing along the second axis, the second separation distance being disposed between the second inward spacing and the second outward spacing; and

wherein the first curing device is spaced closer to the first printhead with the first inward spacing than with the first outward spacing, and wherein the second curing device is spaced closer to the second printhead with the second inward spacing than with the second outward spacing.

17. The apparatus for printing as in claim 16, wherein the first and second inward spacing corresponds with a matte finish, and wherein the first and second outward spacing corresponds with a glossy finish.

18. The apparatus for printing as in claim 17,

wherein the controller is configured to receive a first target gloss level for printing the three-dimensional structural component using the first print material from the first printhead and to receive a second target gloss level for printing the three-dimensional structural component using the second print material from the second printhead;

wherein the controller selects the first separation distance based on the first target gloss level; and

wherein the controller selects the second separation distance based on the second target gloss level.

19. The apparatus for printing as in claim 18, wherein the controller selects an intermediate spacing between the first inward spacing and the first outward spacing for the first printhead when the first target gloss level indicates an intermediate target gloss level between the glossy finish and the matte finish.

20. The apparatus for printing as in claim 15, wherein the first print material comprises one or more pigments and wherein the second print material is clear.

21. A method of printing a three-dimensional structural component with a printhead assembly having a first printhead and a second printhead, comprising:

printing a first print material from the first printhead onto a base;

printing a second structural print material from the second printhead onto the base;

wherein the first printhead comprises a first row of print nozzles of the printhead assembly and wherein the second printhead comprises a second row of print nozzles of the printhead assembly, the second row of print nozzles being parallel with the first row of print nozzles;

receiving a first target gloss level for printing the first print material from the first printhead;

selecting a first spacing between a first curing device of a curing device assembly and the first printhead according to the first target gloss level, wherein the curing device assembly is disposed on a first side of the print assembly, and wherein the first curing device is mounted on a first rail and is movable relative to the first rail and relative to the first printhead along a first axis to the first spacing;

automatically adjusting the first curing device relative to the first rail and relative to the first printhead along the first axis to the first spacing;

receiving a second target gloss level for printing the second structural print material from the second printhead;

selecting a second spacing between a second curing device of the curing device assembly and the second printhead according to the second target gloss level, wherein the second curing device is mounted on a second rail and is movable relative to the second rail and relative to the second printhead along a second axis to the second spacing, the second spacing being independently selectable relative to and different than the first spacing;

automatically adjusting the second curing device relative to the second rail and relative to the second printhead along the second axis to the second spacing; and

curing the first print material and the second structural print material using the curing device assembly.

22. The method of printing as in claim 21, further comprising an actuating system with a controller, a first actuating device, and a second actuating device, wherein the controller and the first actuating device are configured for automatically adjusting the first curing device relative to the first rail along the first axis to the first spacing and wherein the controller and the second actuating device are configured for automatically adjusting the second curing device relative to the second rail along the second axis to the second spacing.

23. The method of printing as in claim 21, wherein the first rail and the second rail are spaced apart from and parallel to each other, wherein the second axis of the second curing device is spaced apart from and parallel to the first axis of the first curing device, wherein the first axis of the first curing device is parallel to a first print axis along which the first printhead moves, and wherein the second axis of the second curing device is parallel to a second print axis along which the second printhead moves.