Inkjet Controller Nozzle Flushing Strategy
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Solution Overview
Problem
Inkjet printing apparatuses with fixed print heads face challenges in efficiently performing flushing operations due to limitations in nozzle arrangement and the need for specialized mechanisms, leading to potential drying of nozzles and interference with printed images, especially in low-resolution printing where ink ejection patterns can be conspicuous.
Innovation Solution
A printing system that includes a controller to determine the need for flushing based on nozzle usage and combine flushing data with printing data, allowing for timed and strategically placed ink ejection to prevent nozzle drying without interfering with the printed material, using a predetermined placement reservation region for the flushing pattern.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flushing is performed using conventional techniques on fixed-head inkjet printing apparatus, then nozzle drying is prevented, but the flushing process interferes with printed images and reduces printing efficiency
Solution Approach 1:
The invention segments the flushing operation by controlling individual nozzles independently. Instead of flushing all nozzles simultaneously, the system identifies and flushes only specific nozzles that are prone to drying, based on their usage patterns. This is achieved through nozzle-specific control signals that enable selective flushing without affecting other nozzles or the overall printing process.
Solution Approach 2:
The system performs preliminary identification of nozzles that require flushing by monitoring their usage status before actual flushing occurs. The controller determines which nozzles need flushing based on predetermined conditions (such as unused nozzles in a printing job) and schedules flushing operations in advance or during appropriate printing intervals, preventing drying before it occurs.
2Device complexity
If all nozzles are made to perform flushing operation simultaneously in fixed-head inkjet printing apparatus, then flushing is simplified, but effective flushing cannot be carried out when certain nozzles are not in use
Solution Approach 1:
The flushing operation is made dynamic rather than static. Instead of requiring all nozzles to flush simultaneously, the system dynamically adjusts which nozzles flush based on real-time printing conditions and nozzle usage patterns. The controller selectively activates flushing for specific nozzles based on their actual need, making the flushing process adaptive to changing printing requirements.
Solution Approach 2:
The invention applies local quality by treating each nozzle differently based on its specific characteristics and usage patterns. Rather than uniform flushing of all nozzles, the system identifies local issues (specific nozzles that are unused or prone to drying) and applies targeted flushing only to those affected areas, improving effectiveness while reducing unnecessary operations.
3Reliability
If flushing is performed in low-resolution printing mode, then nozzle maintenance is achieved, but the ink ejection pattern becomes conspicuous and degrades print quality
Solution Approach 1:
The system applies local quality by making the flushing pattern invisible or inconspicuous in the printed output. The controller designs the flushing ejection pattern to be either completely invisible, extremely faint, or strategically placed in areas that do not affect the visible print quality. This allows nozzle maintenance to occur while maintaining high print quality in the visible printing areas.
Solution Approach 2:
The invention converts the potentially harmful effect of visible flushing patterns into a beneficial outcome. By carefully controlling the flushing ejection pattern, the system makes the flushing process invisible or insignificant in the final print, effectively hiding the maintenance operation from view while still achieving nozzle cleaning benefits.
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 enhances print quality by preventing nozzle drying and allowing flexible flushing operations that do not compromise the visual effect of the printed material, improving overall printing efficiency and quality.
Implementation Method 1
printing is done on predetermined paper by the ejection or the like of fine (misty) ink particles (referred to also as ink droplets and the like) from a plurality of nozzle tips provided in a print head
Implementation Method 2
an inkjet printing apparatus configured to carry out flushing (also known as idle ejection, preliminary ejection and the like) during printing is known in the art, the flushing being the process of forcibly executing an ink ejection operation independent of what is to be originally printed
Data Source
AI summary
During the creation of print job data on a job creation terminal, a flushing pattern placement reservation region is previously arbitrary specified and described in placement condition data. Flushing pattern data is previously stored in a storage part. A flushing judgment part specifies frequency with which ink is ejected from each nozzle of a printing apparatus from rasterized data, to judge whether a flushing operation is needed or not. When the flushing operation is needed, a printing execution instruction part acquires the flushing pattern data for causing the ink ejected from a target nozzle to form a certain flushing pattern, to combine the flushing pattern data with the rasterized data, and the printing apparatus executes printing based on the resultant data obtained by the combination. This achieves the production of a printed material while ensuring the flushing operation.