Method and apparatus for printing using a facetted drum

• US 8,632,145 B2
• Filed: 07/02/2011
• Issued: 01/21/2014
• Est. Priority Date: 06/13/2008
• Status: Expired due to Fees

• Current Assignee: Kateeva, Inc.
• Original Assignee: Kateeva, Inc.
• Inventors: Madigan, Conor Francis, Vronsky, Eliyahu, Ko, Alexander Sou-Kang, Lowrance, Robert B., Buchner, Christopher
• Primary Examiner(s): Martin, Laura
• Assistant Examiner(s): MCMILLION, TRACEY M
• Application Number:
  US13/175,826
• Publication Number:
  US 20120001967A1
• Time in Patent Office: 934 Days
• Field of Search: None
• US Class Current: 347/6
• CPC Class Codes: B41J 2/0057 where an intermediate transfer member receives the ink before transferring it on the printing material

Abstract

The disclosure generally relates to a method and apparatus for printing from a rotating source. In an exemplary embodiment, the disclosure relates to a facetted drum for simultaneously printing multiple pixels. The facetted drum includes a support structure and a plurality of printheads affixed to the support structure, each printhead having at least one microporous structure for receiving a first quantity of liquid ink having dissolved or suspended film material in a carrier fluid and dispensing a second quantity of ink material substantially free of the carrier fluid. The plurality of printheads are positioned proximal to a substrate to simultaneously print a plurality of spatially-discrete and image-resolved pixels on the substrate.

Claims

1. A facet structure for printing multiple pixels, comprising:

a support structure;

a plurality of printheads affixed to the support structure, each printhead having at least one micropore for receiving a first quantity of liquid ink having dissolved or suspended film material in a carrier fluid and dispensing a second quantity of ink material substantially free of the carrier fluid;

wherein the plurality of printheads are positioned proximal to a substrate to simultaneously print a plurality of spatially-discrete and image-resolved pixels on the substrate at about 25-500 pixels per inch.

2. The facetted structure of claim 1, further comprising a flange for receiving a fluid at the support structure.

3. The facetted structure of claim 1, further comprising a driver board coupled to the support structure, the driver board having a processor for actuating ink dispensing from at least one printhead.

4. The facetted structure of claim 1, wherein at least one micropore is a closed micropore.

5. The facetted structure of claim 1, wherein at least one micropore is an open micropore extending through the printhead.

6. The facetted structure of claim 1, wherein at least one printhead of the plurality of printheads comprises an array of micropores and wherein each micropore is spaced apart from an adjacent micropore by about 1-4 μ

m.

7. The facetted structure of claim 1, wherein at least one micropore is about 3 μ

m.

8. A facetted drum system for pixel printing, comprising:

a chuck for receiving a rotating printhead assembly;

a plurality of facets, each facet tangentially affixed to a respective face of the rotating printhead assembly; and

a plurality of printheads, wherein at least one printhead is mounted to each facet;

said at least one printhead having an array of micropores to receive a first quantity of liquid ink;

said liquid ink comprised of dissolved or suspended film material in a carrier fluid and to dispense a second quantity of ink material substantially free of the carrier fluid;

wherein the at least one printhead mounted to each facet can be rotatably positioned proximal to a substrate to simultaneously print a plurality of spatially-resolved pixels.

9. The facetted drum system of claim 8, wherein each facet comprises a facet driver board, a support structure and the plurality of printheads.

10. The facetted drum system of claim 8, wherein the support structure further comprises at least one channel for communicating a fluid to the substrate.

11. The facetted drum system of claim 10, wherein the fluid defines a gas.

12. The facetted drum system of claim 8, further comprising an ink delivery structure for communicating liquid ink to each facet.

13. The facetted drum system of claim 8, further comprising a cleaning station for cleaning each facet after printing.

14. The facetted drum system of claim 8, wherein each printhead further comprises an actuator for dispensing the second quantity of ink material.

15. The facetted drum system of claim 8, wherein each printhead further comprises a heater for dispensing the second quantity of ink material.

16. The facetted drum system of claim 8, further comprising a controller for dictating the rotation of the rotating printhead assembly for receiving a first quantity of liquid ink and for dispensing the second quantity of ink material.

17. The facetted drum system of claim 8, wherein at least one micropore is a closed micropore.

18. The facetted drum system of claim 8, wherein at least one micropore is an open micropore extending through the printhead.

19. The facetted drum system of claim 8, wherein the printheads are arranged to dispense ink to thereby print spatially-discrete and image-resolved pixels on a substrate.

20. A system for printing a film on a substrate, the system comprising:

a microprocessor circuit;

a memory circuit in communication with the microprocessor circuit, the memory circuit storing instructions for the processor circuit to;

(1) meter a quantity of liquid ink to a facet of a drum;

the facet having at least one printhead thereon, wherein the quantity of liquid ink is supplied to the facet from an external ink delivery source;

(2) remove the carrier liquid from the supplied quantity of ink in order to form a substantially liquid-free quantity of ink on the at least one printhead,

(3) evaporate the substantially liquid-free quantity of ink remaining on the at least one printhead; and

(4) direct the vaporized quantity of ink onto the substrate to simultaneously print a plurality of spatially-discrete and image-resolved pixels on the substrate.

21. The system of claim 20, further comprising heating the printhead to remove the carrier liquid.

22. The system of claim 20, wherein the step of metering a quantity of liquid ink further comprises directing an external ink delivery source to meter the quantity of liquid ink onto the printhead.

23. The system of claim 20, wherein the step of metering a quantity of liquid ink further comprises using an air-knife to force the quantity of liquid ink into the printhead.

24. The system of claim 20, wherein the step of removing the carrier liquid from the supplied quantity of ink further comprises heating at least one of the facet or the printhead to a temperature to evaporate the carrier fluid.

25. A method for printing a film from a rotating drum having a plurality of facets, the method comprising:

supplying a quantity of liquid ink to one of the plurality of the facets, the facet supporting a microstructure thereon and the liquid ink defining a carrier liquid having suspended and/or dissolved ink particles;

removing the carrier liquid from the supplied quantity of ink to form a substantially liquid-free quantity of ink on the printhead,

evaporating the substantially liquid-free quantity of ink remaining on the printhead; and

dispensing the vaporized quantity of ink from the printhead onto the substrate;

wherein the drum is rotated such that the facet receives liquid ink at a first orientation while dispensing the vaporized ink at a second orientation.

26. The method of claim 25, further comprising heating the microstructure to remove the carrier liquid.

27. The method of claim 25, wherein the step of supplying a quantity of liquid ink further comprises directing an external ink delivery source to meter the first quantity of liquid ink onto the facet.

28. The method of claim 25, wherein the step of supplying a quantity of liquid ink further comprises directing an external ink delivery source to meter the first quantity of liquid ink onto the microstructure.

29. The method of claim 25, wherein the step of supplying a quantity of liquid ink further comprises using an air-knife to force the supplied quantity of liquid ink into the microstructure.

30. The method of claim 25, wherein the step of removing the carrier liquid from the supplied quantity of ink, further comprises heating at least one of the facet or the microstructure to a temperature to evaporate the carrier fluid.

31. The method of claim 25, wherein the step of directing the vaporized quantity of ink onto the substrate further comprises using an auxiliary flow to direct the vaporized ink onto the substrate.