Inkjet Nozzle Array Defect Compensation for Color Uniformity
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Solution Overview
Problem
Inkjet printing systems face challenges in maintaining color uniformity due to defective nozzles, especially when different arrays of nozzles dispense different material formulations, leading to unintended ratios and properties in the final object.
Innovation Solution
The method involves detecting defective nozzles in one array and disabling corresponding nozzles in another array to maintain the desired ratio of material formulations, ensuring that the dispensing of different material formulations occurs in an interlaced manner to compensate for defective nozzles, even when they dispense different types of materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If defective nozzles are detected and compensated by adjusting material formulation ratios, then color uniformity is improved, but the complexity of the printing system increases due to additional detection and control mechanisms
Solution Approach 1:
The patent implements a feedback mechanism where the printing system detects defective nozzles and automatically adjusts material formulation ratios to compensate for the defects. This closed-loop control ensures color uniformity while managing system complexity through automated response to detected issues.
Solution Approach 2:
The system changes material formulation parameters (ratios of different materials) dynamically based on nozzle defect detection. By adjusting these parameters in real-time, the system maintains color uniformity without requiring physical modification of the printing hardware.
2Adaptability or versatility
If multiple nozzle arrays are used to dispense different material formulations, then printing versatility is improved, but the difficulty of detecting and measuring defective nozzles increases
Solution Approach 1:
The patent divides the nozzle system into multiple independent arrays, each responsible for specific material formulations. This segmentation allows targeted detection and compensation strategies for each array, making defect detection more manageable despite the increased number of nozzles.
Solution Approach 2:
The system uses reference patterns or templates to compare against actual nozzle output, enabling detection of defective nozzles by identifying deviations from expected behavior. This copying approach simplifies the detection process by providing clear benchmarks for comparison.
3Manufacturing precision
If corresponding nozzles in multiple arrays are disabled to maintain material ratios, then color uniformity is improved, but the productivity of the printing system decreases due to reduced number of functional nozzles
Solution Approach 1:
The patent applies partial action by disabling only the minimum number of nozzles required to maintain proper material ratios, rather than shutting down entire arrays. This selective approach preserves as much printing capability as possible while ensuring color uniformity.
Solution Approach 2:
The system dynamically adjusts which nozzles are active based on real-time defect detection and material ratio requirements. This dynamic reconfiguration allows the system to optimize between productivity and precision by enabling the maximum number of nozzles that maintain proper formulation ratios.
Data Source
Figure 1A
Figure 1B~1C
Figure 1D
AI summary
A method of printing comprises: detecting a defective nozzle (42a) in a first array of nozzles (122a); disabling a nozzle (42b) in a second array of nozzles (122b); dispensing a first material formulation from nozzles of the first array (122a), other than the defective nozzle (42b); and dispensing a second material formulation from nozzles of the second array (122b), other than the disabled nozzle (42b).