Gel Ink Dot Union for Stripe Defect Prevention
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Solution Overview
Problem
Line-head-type inkjet image-forming methods using gel ink face challenges in preventing stripe defects due to nozzle failures, as existing solutions require complex control of ejection operations across multiple nozzles.
Innovation Solution
The method involves setting a first coverage rate for inkjet nozzles less than 100% to allow newly ejected gel ink dots to unite with existing dots on the recording medium, using gel ink with a crystalline gelling agent, colorant, and polymer dispersant, and controlling the dot diameter and coverage rate to prevent image defects, adhering to the formula 2.7≤D/(2.54×104/R)≤3.5, where R is the image resolution and D is the ink droplet diameter.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the coverage rate is increased to 100% to prevent stripe defects, then image completeness improves, but productivity decreases and control complexity increases
Solution Approach 1:
The patent changes the coverage rate parameter from the conventional 100% to a specific range of 5-50%, and adjusts the dot diameter parameter accordingly to satisfy the formula D/(2.54×10^4/R)≥0.05. This parameter optimization allows dots to overlap and unite, preventing stripe defects while maintaining high productivity through reduced ejection frequency.
2Reliability
If special control of ejection operation is applied to adjacent nozzles to prevent stripe defects, then image quality improves, but control complexity increases
Solution Approach 1:
The patent applies local quality by setting different coverage rates for different nozzle groups. Specifically, nozzles adjacent to the center are set with coverage rates of 5-50%, while other nozzles use conventional coverage rates. This localized adjustment prevents stripe defects around the center region without requiring complex control of all nozzles, thus reducing overall control complexity.
3Reliability
If dot diameter is increased to allow dot union, then stripe defect prevention improves, but manufacturing precision requirements increase
Solution Approach 1:
The patent performs preliminary action by pre-calculating and setting the dot diameter to satisfy the formula D/(2.54×10^4/R)≥0.05 before the ejection process. This ensures that dots are sufficiently large to unite and prevent stripe defects, while the precise formula-based approach actually reduces the need for high-precision real-time control during manufacturing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach effectively suppresses the occurrence of image defects and stripe defects by simplifying the control of ink ejection, ensuring high-quality image formation with improved productivity and adhesion.
Implementation Method 1
the first coverage rate is less than 100% and set to allow dots of newly ejected gel ink to unite with dots of the gel ink already landed on the recording medium
Implementation Method 2
the gel ink has a contact angle of 15 to 30° on the recording medium
Implementation Method 3
The gel ink includes a crystalline gelling agent, a colorant, and a polymer dispersant
Data Source
AI summary
A line-head-type inkjet image-forming method includes ejecting a gel ink to a recording medium at a first coverage rate that is less than 100% and set to allow dots of newly ejected gel ink to unite with dots of the gel ink already landed on the recording medium. The gel ink contains a specific amount of a polymer dispersant based on the amount of the colorant and has a specific contact angle on the recording medium. The gel ink is ejected from nozzles so as to form dots with a diameter slightly larger according to the resolution of the image to be formed.