Granted Patent B2

US 12,552,178 · App. 18/448,810 · Granted Feb 17, 2026

Inventors: Christopher R. Hauf (Belmont, CA); David Darrow (Pleasanton, CA); David Donovan (Newark, CA)

Assignee: Kateeva, Inc.

B41J2/2135H04N1/00761

Abstract

Claims (91)

1 . A printing system, comprising:

a substrate support;

a print support;

a printhead assembly movably coupled to the print support, the printhead assembly comprising:

a plurality of nozzles extending in a first direction towards the substrate support; and

a plurality of marks; and

an imager coupled to the print support, the printhead assembly and imager being relatively movable, and the imager oriented in a direction opposite to the first direction for capturing an image including the plurality of marks,

wherein

the printhead assembly is positionable in an imaging field of the imager to enable the imager to capture the image while the printhead assembly is passing by the imager, and

the imager is a line scan imager.

2 . The printing system of claim 1 , further comprising:

a controller to

map the positions of the plurality of nozzles in the printhead assembly to corresponding positions in a frame of reference of the printing system, and

control ejection of print material from the plurality of nozzles based on the mapped positions of the nozzles in the frame of reference of the printing system.

3 . The printing system of claim 2 , wherein

the controller detects, from the image captured by the imager,

the plurality of marks, and

one of the nozzles, and

determines and maps the positions of the plurality of nozzles in the printhead assembly based on the detected plurality of marks, and

the detected nozzle.

4 . The printing system of claim 1 , wherein

the printhead assembly further comprises a plurality of printheads, each printhead comprising a portion of the nozzles, each printhead having a plurality of printhead marks with predetermined positions relative to the nozzles, and

the printing system further comprises a controller to

detect, from the image captured by the imager,

the plurality of marks, and

the plurality of printhead marks, and

determine the positions of the nozzles in the printhead assembly, based on

the detected plurality of marks,

the detected plurality of printhead marks, and

the predetermined positions of the plurality of printhead marks relative to the plurality of nozzles.

5 . The printing system of claim 1 , wherein

the imager has a fixed position relative to the substrate support.

6 . The printing system of claim 5 , wherein

the nozzles are arranged in at least one row along the cross-scan direction.

7 . The printing system of claim 6 , further comprising:

a controller to control the line scan imager to capture the image to include all of the plurality of dispensing nozzles in a single pass of the printhead assembly in the cross- scan direction by the line scan imager.

8 . A printing method, comprising:

capturing, by an imager, an image of a plurality of housing marks of a printhead assembly housing a plurality of removable printheads and a printhead mark on each printhead, each printhead having a plurality of nozzles;

detecting the plurality of housing marks and printhead marks in the image captured by the imager;

determining positions of at least a portion of the nozzles based on the detected housing marks and printhead marks;

based on the positions of the nozzles, ejecting print material from the nozzles onto a substrate while moving the substrate relative to the printhead assembly.

9 . The printing method of claim 8 , further comprising:

mapping the determined positions of the nozzles to a frame of reference,

wherein the ejecting print material from the nozzles is based on the mapped positions of the plurality of nozzles.

10 . The printing method of claim 8 , further comprising:

detecting, from the image captured by the imager, a nozzle of the plurality of nozzles,

wherein said determining the positions of the plurality of dispensing nozzles in the printhead assembly is also based on

the detected nozzle.

11 . The printing method of claim 8 , wherein the imager is movable relative to the substrate support.

12 . The printing method of claim 8 , wherein

said capturing the image is performed while the printhead assembly is moved in a cross-scan direction to pass by the imager.

13 . The printing method of claim 12 , wherein

the imager is a line scan imager that has a plurality of image sensors arranged in a single line along a scan direction transverse to the cross-scan direction,

the plurality of nozzles is arranged in at least one row along the cross-scan direction, and

the image is captured by the line scan imager in a single pass of the printhead assembly by the line scan imager.

14 . The printing method of claim 13 , wherein the image sensors have resolution of about 0.1 μm.

15 . A printing system, comprising:

a substrate support;

a print support that extends across the substrate support;

a printhead assembly coupled to the print support, the printhead assembly comprising:

a printhead having a plurality of nozzles facing the substrate support;

a housing; and

a plurality of marks on the housing;

a line scan imager the line scan imager and the printhead assembly relatively movable to position the nozzles and the plurality of marks within a field of view of the line scan imager for capturing an image, while the printhead assembly and the line scan imager are in relative movement, including the plurality of marks and the nozzles; and

a controller to control ejection of print material from the nozzles based on the image.

16 . The printing system of claim 15 , wherein the line scan imager is a first imager, the image is a first image, the marks are first marks, and the printing system further comprises:

a second imager that is movable for capturing a second image of a substrate disposed on the substrate support,

wherein the controller

detects, from the second image, a plurality of second marks indicating a print region of the substrate,

maps positions of the print region as indicated by the second marks to corresponding positions in a frame of reference of the printing system,

maps the positions of the plurality of nozzles in the printhead assembly to corresponding positions in the frame of reference of the printing system, and

controls the ejection of print material from the nozzles based on the mapped positions of the nozzles and the print region in the frame of reference of the printing system.

17 . The printing system of claim 15 , wherein the controller

detects, from the image,

the marks, and

at least one of the nozzles, and

determines the positions of the nozzles based on

the detected marks, and

the detected nozzle.

18 . The printing system of claim 15 , wherein the marks are first marks, and

the printhead assembly further comprises a plurality of third marks having predetermined positions relative to the nozzles, and

the controller

detects, from the image,

the first marks, and

the third marks, and

determines the positions of the nozzles in the printhead assembly, based on

the detected first marks,

the detected third marks, and

the predetermined positions of the third marks relative to the nozzles.

19 . The printing system of claim 15 , wherein the imager comprises a plurality of image sensors each having a resolution of about 0.1 μm.

20 . The printing system of claim 15 , wherein the nozzles are located in a nozzle surface of the printhead assembly, and further comprising a light source selected based on optical properties of the nozzle surface, the nozzles, the marks, or any combination thereof.

Continuity (4)

References Cited (42)