Inkjet Nozzle Array Calibration via Color Patch Analysis
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Solution Overview
Problem
Inkjet printers face variability in nozzle manufacturing, leading to deviations in ink drop trajectories and inconsistent print quality due to slight deformations during the assembly of dies onto pen bodies, resulting in different ink coverage and print quality issues across nozzle arrays.
Innovation Solution
A printing apparatus with an array of nozzles and a controller that instructs the nozzles to print color patches using different nozzle setting values, receives sensor signals for color saturation and density measurements, and selects a print mode configuration based on these measurements to optimize ink placement and print quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional nozzle assembly methods are used, then manufacturing simplicity is maintained, but ink drop trajectory accuracy deteriorates due to die deformation
Solution Approach 1:
The patent applies preliminary action by pre-calibrating each nozzle's trajectory and drop ejection characteristics before the actual printing process. The system performs initial tests to determine optimal nozzle settings for each position in the array, storing this calibration data for use during normal operation. This pre-characterization approach compensates for manufacturing variations without requiring complex real-time adjustments.
Solution Approach 2:
The patent utilizes parameter changes by dynamically adjusting nozzle settings (such as voltage, pulse width, or pressure) based on measured performance characteristics. The system modifies ejection parameters for each nozzle according to its specific trajectory accuracy and drop placement precision, allowing optimization of print quality while maintaining manufacturing simplicity.
2Manufacturing precision
If multiple nozzle settings are tested, then print quality optimization is improved, but measurement and testing complexity increases
Solution Approach 1:
The patent applies self-service by enabling the printing system to automatically characterize and optimize its own nozzle performance without external intervention. The system performs self-diagnostic tests, measures drop placement accuracy, and autonomously determines optimal operating parameters for each nozzle. This automation eliminates the need for complex external testing equipment and manual calibration procedures.
Solution Approach 2:
The patent implements feedback mechanisms where the system continuously monitors print quality metrics and uses this information to adjust nozzle settings. Measurement data from color patches or test patterns is fed back to the control system, which then modifies nozzle ejection parameters to achieve optimal print quality consistency across all nozzles.
3Manufacturing precision
If color saturation measurements are used for optimization, then ink coverage consistency is improved, but measurement precision requirements increase
Solution Approach 1:
The patent applies parameter changes by using color saturation measurements as feedback to adjust ink ejection parameters. The system modifies nozzle voltage, pulse duration, or fluid pressure based on measured color density and saturation values, thereby achieving consistent ink coverage. This dynamic parameter adjustment compensates for variations in ink formulation, substrate properties, and nozzle performance.
Solution Approach 2:
The patent replaces direct mechanical measurement of ink drop placement precision with optical measurement methods. Instead of physically measuring drop positions or using complex mechanical sensors, the system uses color sensors or spectrophotometers to measure optical properties (saturation, density) of printed patches, which indirectly reflect ink coverage accuracy. This substitution simplifies the measurement system while maintaining precision.
Data Source
AI summary
An example of a system for selecting print mode configurations is disclosed. The example disclosed herein comprises an array of nozzles to eject ink, and a controller. The controller is to instruct the array of nozzles to print a plurality of color patches, each color patch being printed using different nozzle setting values. Also, the controller is to receive a sensor signal from each color patch from a color sensor. The controller is further to derive color saturation and/or density measurement information from the sensor signals; and to select a print mode configuration based on the color saturation and/or density measurement information.