Defective Printer Nozzle Compensation Through Image Data Rerouting
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Solution Overview
Problem
Existing techniques for compensating for defective printer nozzles in inkjet printers, such as cleaning or replacing them, disrupt printing processes and increase costs, and slower print modes with redundancy reduce productivity.
Innovation Solution
Rerouting image data to fully or partially complementary nozzles to compensate for defective printer nozzles, allowing continuous printing without halting operations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cleaning or replacing defective printer nozzles is performed, then print quality is improved, but printing operations are disrupted and productivity decreases
Solution Approach 1:
The system performs preliminary detection of defective nozzles and pre-computes compensation mappings before actual printing. By detecting defective nozzles in advance and creating a mapping between defective nozzles and complementary nozzles beforehand, the system eliminates the need to halt printing for nozzle maintenance, thus maintaining both print quality and productivity
Solution Approach 2:
The patent introduces an intermediary compensation mechanism where complementary nozzles act as mediators to deposit ink for pixels that would otherwise be printed by defective nozzles. This intermediary approach allows the printing process to continue uninterrupted while still achieving the desired print quality through the mapping and compensation of defective nozzle output
2Reliability
If slower print modes with redundancy are used, then defective nozzle compensation is improved, but productivity decreases
Solution Approach 1:
The system changes the parameter of nozzle utilization by dynamically mapping defective nozzles to complementary nozzles based on their printing capabilities. By adjusting which nozzles are activated and how image data is distributed across available nozzles, the system achieves reliable defective nozzle compensation while maintaining high printing speed without requiring slower print modes
3Manufacturing precision
If existing nozzle compensation techniques are implemented, then print quality is maintained, but operational costs increase
Solution Approach 1:
The system implements self-service by automatically detecting defective nozzles, computing compensation mappings, and adjusting print output distribution without requiring manual intervention for nozzle maintenance or replacement. This automated self-correction mechanism maintains print quality while reducing operational costs by eliminating the need for costly nozzle cleaning, replacement, or manual recalibration processes
Data Source
AI summary
The disclosed embodiments include a method to compensate for defective printer nozzles. The method can include detecting a defective printer nozzle and initiating a print job including image data of the defective printer nozzle for a pixel location of an image. The image is to be printed in accordance with a print mask that maps printer nozzles to pixel locations of the image. The method can include modifying the image to print the image data in a neighboring pixel location relative to the pixel location of the image and printing the modified image.