Hybrid Drop Weight Printing for Inkjet Press Speed and Quality
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Solution Overview
Problem
Inkjet web presses face a tradeoff between print quality and speed, particularly when printing in mono/black mode, as the higher number of black printheads compared to color printheads leads to underutilization of quality capabilities in single drop weight (SDW) print mode, limiting print speed when using only high drop weight (HDW) nozzles.
Innovation Solution
Implementing a hybrid print mode that enables dual drop weight (DDW) printing from black printheads and SDW printing from color printheads, allowing black printheads to use both high and low drop weight nozzles while color printheads use only high drop weight nozzles, maximizing quality and speed.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If single drop weight (SDW) print mode is used with high drop weight (HDW) nozzles only, then print speed is improved, but print quality deteriorates due to underutilization of low drop weight nozzle capabilities
Solution Approach 1:
The patent segments the printhead functionality by implementing separate high drop weight (HDW) and low drop weight (LDW) nozzle arrays, allowing independent control and optimization of each nozzle type for different print quality and speed requirements
Solution Approach 2:
The system dynamically selects between SDW mode (using only HDW nozzles for high speed) and DDW mode (using both HDW and LDW nozzles for high quality) based on print job requirements, enabling adaptive optimization of print parameters
2Manufacturing precision
If dual drop weight (DDW) print mode is used with both high and low drop weight nozzles, then print quality is improved, but print speed deteriorates due to increased complexity of coordinating multiple nozzle types
Solution Approach 1:
The printhead is segmented into distinct HDW and LDW nozzle arrays, allowing the system to selectively activate only the necessary nozzle type for each print job, thereby maintaining high print quality while avoiding the speed penalties associated with coordinating all nozzle types
Solution Approach 2:
The system changes operational parameters by switching between SDW and DDW modes depending on whether print quality or print speed is the primary requirement, optimizing performance for different application scenarios
3Productivity
If twice as many black printheads as color printheads are configured, then mono/black printing speed is improved, but quality capabilities are underutilized in SDW mode
Solution Approach 1:
The black printheads are designed with multi-functionality, capable of operating in both SDW mode (using only HDW nozzles for high-speed mono printing) and DDW mode (using both HDW and LDW nozzles for high-quality color and graphic printing), thereby maximizing the utility of the additional black printhead configuration
Solution Approach 2:
The system changes operational modes to match print job requirements, switching between SDW and DDW configurations to ensure that the additional black printheads contribute to both speed and quality optimization depending on the specific printing task
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 hybrid mode enhances overall print quality and achieves maximum available print speed by effectively utilizing both high and low drop weight nozzles in black and color printheads, respectively, thereby optimizing performance in inkjet web presses with twice as many black as color printheads.
Implementation Method 1
The drop generators share a common ink supply and include heater resistors and nozzles arranged in alternating HDW and LDW patterns
Data Source
AI summary
In an example implementation, a method of dual and single drop weight printing includes operating a printing system in a hybrid drop weight print mode to enable ejecting black ink from high drop weight nozzles and low drop weight nozzles, and ejecting color ink from high drop weight nozzles but not from low drop weight nozzles.