Inkjet Head Module Nozzle Deviation Compensation
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Solution Overview
Problem
Ink-jet recording apparatuses with line heads composed of multiple modules experience image quality degradation, such as gloss differences and streaks, in overlapping areas due to varying nozzle positions and ink ejection timing, leading to inconsistent image quality across the entire overlapping region.
Innovation Solution
The apparatus includes a transporter and a recording controller that adjusts the mixing ratio of ink ejection from upstream and downstream nozzles based on stored positional deviation information, ensuring uniform image formation by aligning the average nozzle position across the overlapping area, thereby minimizing image incongruities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a line head with multiple head modules is used to increase printing width, then productivity is improved, but image quality degradation occurs in overlapping areas due to varying nozzle positions and ejection timing
Solution Approach 1:
The patent applies local quality by implementing different ejection control strategies for different regions of the head modules. Specifically, in overlapping areas where multiple head modules print simultaneously, the system adjusts the ejection timing and mixing ratios locally to compensate for positional deviations, while non-overlapping areas use standard ejection control. This regional differentiation ensures uniform image quality across the entire printing width despite the modular structure.
Solution Approach 2:
The patent implements dynamics by making the ejection control system adaptive and variable rather than fixed. The recording controller dynamically adjusts ejection timing and mixing ratios based on real-time positional deviation data for each nozzle. This dynamic adjustment allows the system to maintain consistent image quality across different head modules and overlapping regions, resolving the contradiction between using multiple modules for increased width and maintaining uniform image quality.
2Device complexity
If fixed ejection timing is used for simplicity, then device complexity is reduced, but image incongruity occurs due to positional deviations of nozzles
Solution Approach 1:
The patent applies feedback by incorporating positional deviation information into the ejection control system. The recording controller receives and processes positional deviation data for each nozzle, then uses this feedback to dynamically adjust ejection timing and mixing ratios. This feedback mechanism enables the system to compensate for manufacturing variations in nozzle positions without requiring complex mechanical adjustments, thereby maintaining image quality while avoiding excessive device complexity.
3Ease of operation
If uniform mixing ratio is applied across all nozzles, then ease of operation is improved, but image incongruity such as gloss difference and streak occurs in overlapping areas
Solution Approach 1:
The patent applies local quality by implementing spatially varying mixing ratios based on the specific location of each nozzle within the head modules. In overlapping areas, the system calculates and applies different mixing ratios for upstream and downstream nozzles to compensate for their respective positional deviations and ejection timing differences. This localized control strategy ensures uniform image quality and eliminates gloss differences and streaks, while the automated calculation process maintains ease of operation.
Data Source
AI summary
An ink-jet recording apparatus includes: head modules each including nozzles disposed in a row; a transporter that moves a recording medium with respect to the head modules in a direction intersecting with an arrangement direction of the nozzles; a recording controller that causes the nozzles to eject ink onto the recording medium and to form a dot based on image data; and a memory that stores arrangement position information indicating individual positional deviations of the nozzles in a relative movement direction of the head modules with respect to the recording medium. The head modules are disposed in the arrangement direction of the nozzles. The transporter causes a same point of the recording medium to pass through a position where upstream and downstream nozzles that correspond to two adjacent head modules eject ink.