Ink Jet Gap Adjustment Using Ink Mark Copying
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Solution Overview
Problem
Existing gap adjustment methods for ink jet devices require expensive sensors and are inconvenient due to the need for recalibration with environmental changes, especially when precise adjustments of less than 0.1 mm are necessary.
Innovation Solution
A gap adjustment method that involves discharging ink onto a thin film attached to the landing target object while reciprocating the carriage, forming check patterns to compare actual measurement values with predetermined optimum values, allowing for gap length adjustment without expensive sensors and reducing the need for recalibration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If visual adjustment using a scale is used to adjust the gap length, then the device configuration remains simple, but the measurement precision cannot achieve the required accuracy of 0.1 mm or smaller
Solution Approach 1:
The patent uses ink droplets to create mark patterns on the landing target object as a copy/reference of the actual gap distance. By measuring the distance between these ink marks after discharge, the system indirectly measures the gap length with high precision without requiring complex sensors during the measurement process itself
Solution Approach 2:
The patent replaces complex optical measurement systems (photosensors) with a simpler ink-based marking system. The ink droplets serve as physical markers that record position information, allowing gap measurement through simple distance measurement of the marks rather than through complex optical detection mechanisms
2Measurement precision
If photosensor-based gap measurement is used to achieve high precision, then the measurement precision improves, but the device complexity and cost increase due to expensive and complex mechanisms
Solution Approach 1:
Instead of using photosensors to directly measure and display gap distance, the system uses ink droplets to create a permanent mark pattern that copies the positional information. This mark pattern serves as a reference that can be measured afterward with simple tools, eliminating the need for complex real-time optical measurement systems
Solution Approach 2:
The patent uses disposable ink droplets as measurement markers rather than expensive, durable photosensors. The ink marks are temporary and consumable, but they provide sufficient measurement precision for gap adjustment without requiring investment in expensive sensing equipment
3Measurement precision
If calibration curves are recreated according to environmental changes to maintain accuracy, then the measurement precision is maintained, but the ease of operation deteriorates due to poor convenience
Solution Approach 1:
The patent performs preliminary gap adjustment using the ink mark method before actual printing operations. The ink marks provide a permanent reference that remains valid across different environmental conditions, eliminating the need for repeated calibration curve creation when environmental changes occur
Solution Approach 2:
The system changes the measurement approach from environmental-sensitive optical measurements to environmental-insensitive physical mark measurements. The ink marks on the landing target object provide a stable reference that is not affected by environmental changes, allowing gap adjustment to be performed once with lasting accuracy
Data Source
AI summary
A gap adjustment method of an ink jet device includes a head unit with an ink discharge port that discharges ink, a carriage that is provided with the head unit and moves in a main scanning direction, a print medium provided with a gap with respect to the ink discharge port, and a gap driving unit that adjusts a length of the gap. The gap adjustment method includes a discharging process (step ST4) and a gap adjusting process (step ST5 to step ST56). In the discharging process (step ST4), ink is discharged in each of a forward path and a backward path while reciprocating the carriage in the main scanning direction. In the gap adjusting process, a forward path landing position and a backward path landing position, and an optimum landing position determined in advance are compared, and the length of the gap is adjusted with the gap driving unit.