Inkjet Nozzle Flushing via Adaptive Dot Pattern Assignment
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Solution Overview
Problem
Ink-jet image forming apparatuses face issues with ink clogging at nozzle ejection holes due to drying or other reasons, leading to improper printing, and existing methods for preventing clogging are not fully effective in stabilizing ink ejection and reducing ink bleed.
Innovation Solution
An image forming apparatus with a recording head, storage device, and control device that detects image areas, counts overlapping dots in different dot patterns, and assigns these patterns for forcible ink ejection to minimize clogging and ink bleed by optimizing the frequency and color of ink ejections based on the detected image data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If flushing is executed frequently to prevent ink clogging, then nozzle reliability is improved, but ink bleed increases and image quality deteriorates
Solution Approach 1:
The patent applies local quality by selecting different dot patterns for flushing based on the specific image area being printed. Instead of using a uniform flushing pattern, the system analyzes the image data and assigns dot patterns with appropriate dot densities to different regions. This allows flushing to be optimized locally for each image area, preventing ink clogging where needed while minimizing ink bleed in other areas, thus resolving the contradiction between nozzle reliability and image quality.
Solution Approach 2:
The patent implements dynamics by making the flushing dot pattern selection adaptive and variable rather than static. The control device dynamically selects from multiple dot patterns with different dot densities based on real-time analysis of image data. This dynamic adjustment allows the system to optimize flushing frequency and pattern according to the specific printing conditions, preventing clogging in high-risk areas while reducing unnecessary flushing in low-risk areas, thereby balancing nozzle reliability with ink bleed prevention.
2Reliability
If flushing is executed to stabilize ink ejection, then printing reliability is improved, but ink consumption increases
Solution Approach 1:
The patent applies partial action by executing flushing only in necessary image areas and with optimized dot patterns rather than uniform flushing across the entire print area. The control device analyzes image data to identify regions where flushing is actually needed to prevent clogging, and applies flushing patterns with appropriate dot densities only to those regions. This partial flushing approach maintains printing reliability in critical areas while significantly reducing overall ink consumption compared to comprehensive flushing.
Solution Approach 2:
The patent implements parameter changes by varying the dot pattern parameters (dot density, size, distribution) for flushing based on image characteristics. Instead of using a fixed flushing pattern, the system selects from multiple dot patterns with different parameters optimized for different printing conditions. This allows the flushing operation to adapt its ink ejection parameters to match the specific image being printed, maintaining reliability while minimizing unnecessary ink consumption.
3Manufacturing precision
If multiple dot patterns are used for flushing, then image quality is improved by reducing ink bleed, but device complexity increases
Solution Approach 1:
The patent applies segmentation by dividing the flushing operation into multiple discrete dot patterns that can be independently selected and applied to different image areas. Instead of using a single complex flushing pattern, the system segments the flushing function into several simpler dot patterns with different characteristics (dot density, size, distribution). The control device selects and applies the appropriate segmented pattern to each image region, achieving high image quality through coordinated use of multiple simple patterns rather than one complex pattern.
Solution Approach 2:
The patent uses copying by creating multiple simplified dot patterns that replicate essential flushing functions with different parameters. Rather than developing one complex adaptive flushing system, the invention copies the basic flushing function into multiple distinct dot patterns, each optimized for specific conditions. This allows the control device to select from pre-defined pattern copies rather than generating complex patterns in real-time, reducing control complexity while maintaining image quality.
Data Source
AI summary
An image forming apparatus includes a recording head that ejects inks of different colors on a recording medium to form an image based on image data, a storage device that stores a plurality of different dot patterns for flushing, and a control device that functions as: a controller that allows the recording head to make flushing; an image area detector that detects an image area in the image data; an overlapping dot counter that counts a number of overlapping dots for each of the plurality of dot patterns according to which flushing is to be made on the image area, the number of overlapping dots being a number of dots in the dot pattern of the ink ejected on the image area; and a dot pattern assignor that assigns, according to the number of overlapping dots, the respective dot patterns for use in flushing with the inks of different colors.