Inkjet Nozzle Flushing via Coverage-Based Masking
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Solution Overview
Problem
Current nozzle flushing methods in inkjet printers often compromise image quality, require excessive ink usage, or slow down printing speed, as they either leave visible lines, cause background noise, or are computationally intensive, and fail to account for varying nozzle usage frequencies.
Innovation Solution
A method that calculates a flushing mask based on the coverage per unit area for multiple color planes, allowing for random and visually pleasing nozzle flushing independent of nozzle ejection counts, minimizing ink usage and preserving image integrity by integrating flushing patterns with print job data without affecting throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a line is printed across the top or bottom of each page to flush nozzles, then nozzle clogging is prevented, but a large colored line is left at the bottom of every page
Solution Approach 1:
The patent applies local quality by differentiating flushing requirements for different nozzles based on their usage patterns. Instead of uniformly flushing all nozzles, the system identifies and flushes only those nozzles that are prone to clogging, determined by analyzing print job data to find nozzles with low usage frequency or specific color plane deficiencies. This targeted approach prevents visible lines while maintaining nozzle functionality.
2Reliability
If drops are fired randomly from all nozzles at a specified frequency, then nozzle clogging is reduced, but excessive background noise is caused and color accuracy is altered
Solution Approach 1:
The patent implements local quality by customizing flushing patterns for individual nozzles or nozzle groups based on their specific usage characteristics. The system analyzes print job data to determine which nozzles require flushing and at what frequency, rather than applying a uniform random flushing pattern to all nozzles. This selective approach maintains color accuracy while preventing clogging.
3Manufacturing precision
If intelligent flushing methods are used to hide color ink droplets under black ink, then image quality is preserved, but additional data processing is required slowing down printing
Solution Approach 1:
The patent applies preliminary action by performing nozzle flushing during the rasterization phase, before the actual printing process. The system analyzes print job data and generates flushing patterns that are integrated into the print data stream in advance. This approach preserves image quality while minimizing impact on printing speed, as the computational work is done during the already-necessary rasterization step rather than adding a separate processing stage.
4Reliability
If all nozzles are flushed at the same frequency, then nozzle functionality is maintained, but ink is wasted on nozzles that do not need frequent flushing
Solution Approach 1:
The patent implements local quality by differentiating flushing frequencies for different nozzles based on their usage patterns. The system analyzes print job data to identify nozzles with low usage frequency or specific color plane deficiencies and targets those for flushing. Nozzles that are frequently used or not prone to clogging are flushed less frequently or not at all, significantly reducing ink waste while maintaining nozzle functionality.
5Manufacturing precision
If flushing patterns are integrated with print job data, then image integrity is preserved, but computational complexity increases
Solution Approach 1:
The patent applies preliminary action by integrating flushing pattern generation into the rasterization phase, which is already a necessary step before printing. The system analyzes print job data and generates flushing patterns that are merged with the print data stream during this preliminary processing stage. This approach preserves image integrity while managing computational complexity by utilizing the existing rasterization workflow rather than adding a separate complex processing stage.
Data Source
AI summary
A method is disclosed. The method includes receiving print job data, rasterizing the print job data to generate image data for each page of the print job data to be printed, calculating a coverage per unit area for two or more color planes of each page of the image data and calculating a flushing mask to flush nozzles of the inkjet print head.