Inkjet Printer Auxiliary Layer Dot Area Control
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Solution Overview
Problem
Inkjet printing on various base materials faces challenges such as cockling, ink fixation issues, and decreased image accuracy due to the use of a 100% dot area rate for undercoat layers, particularly on paper and other materials where ink droplets overspread or penetrate excessively.
Innovation Solution
An inkjet printer with an image-forming part that creates an auxiliary layer using auxiliary ink, determining the proper dot area rate based on the type and basis weight of the base material and the attributes of the image, allowing for precise image formation by adjusting the dot formation state of the image-forming ink.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a 100% dot area rate is used for undercoat layer printing, then complete coverage is achieved, but cockling occurs and image accuracy decreases
Solution Approach 1:
The patent applies parameter changes by adjusting the dot area rate of the undercoat layer from a fixed 100% to variable rates (50-70%) based on image characteristics and base material properties. The control unit determines appropriate dot area rates by referencing stored data that correlates image attributes (picture, character, barcode) with optimal undercoat parameters, thereby preventing cockling while maintaining sufficient coverage for accurate image formation.
2Quantity of substance
If a 100% dot area rate is used for undercoat layer printing, then complete coverage is achieved, but ink fixation becomes inappropriate
Solution Approach 1:
The patent changes the parameter of dot area rate from fixed to variable, setting it between 50-70% based on image type and base material characteristics. This optimized parameter range provides sufficient undercoat coverage to ensure proper ink fixation without excessive ink application that would cause cockling, thereby improving reliability of the fixation process.
Solution Approach 2:
The patent applies partial action by using a dot area rate less than 100% (specifically 50-70%) for undercoat layer printing. This partial coverage is sufficient to provide the necessary adhesive properties for image-forming ink fixation while avoiding the harmful effects of complete coverage, thus achieving appropriate fixation without excess ink application.
3Quantity of substance
If auxiliary ink is applied to all positions, then complete base material coverage is achieved, but auxiliary ink consumption increases
Solution Approach 1:
The patent applies local quality by varying the dot area rate of auxiliary ink application based on local image characteristics and base material properties. Different regions receive different undercoat densities (50-70% dot area rate) according to their specific requirements, rather than uniform 100% coverage. This localized optimization reduces auxiliary ink consumption while maintaining sufficient coverage where needed for proper image formation.
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 enables highly precise image formation on various base materials while minimizing auxiliary ink consumption and preventing cockling, with the ability to form images with high accuracy and reduced auxiliary ink usage.
Implementation Method 1
an image-forming part that forms an auxiliary layer on a base material by ejecting droplets of an auxiliary ink toward the base material and forms an image on the auxiliary layer by ejecting droplets of an image-forming ink toward the base material
Data Source
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AI summary
An inkjet printer includes an image-forming part, forming an auxiliary layer on a base material by ejecting droplets of auxiliary ink and forming an image on the auxiliary layer by ejecting droplets of image-forming ink, the auxiliary ink changing a dot formation state of droplets of the image-forming ink. In a storage part, a reference table that associates each of a plurality of types of base materials with a proper dot area rate to be used when forming the auxiliary layer is stored. In a dot-area-rate determination part, a dot area rate to be used when forming the auxiliary layer on a target base material is determined as an auxiliary ink dot area rate by referencing the reference table using the type of the target base material. This enables the inkjet printer to form a highly precise image on various base materials.