Method and apparatus for printing using a facetted drum
View Patent ↗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.
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 μm.
7. The facetted structure of claim 1 , wherein at least one micropore is about 3 μm.
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.