Inkjet Nozzle Test Pattern Imaging for Abnormality Detection
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Solution Overview
Problem
Existing inkjet printing apparatuses face challenges in accurately determining nozzle abnormalities, which can lead to defects in printed images due to issues like constant discharge, non-discharge, and nozzle bending, without effective methods for precise detection and correction.
Innovation Solution
A liquid discharge apparatus and method that includes discharging different amounts of liquid per unit area to form a test pattern, capturing the pattern image, and performing image processing to detect nozzle abnormalities, enabling precise determination of nozzle states such as normal, constant discharge, non-discharge, and bending.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a standard amount of liquid is discharged per unit area onto the detection target member, then the test pattern formation is simple and quick, but the detection precision of nozzle abnormalities is insufficient
Solution Approach 1:
The patent applies parameter changes by varying the liquid discharge amount per unit area when forming test patterns. Specifically, it discharges a first liquid at a first discharge amount and a second liquid at a second discharge amount that is larger than the first. This parameter variation enhances the visibility and detectability of nozzle abnormalities such as constant discharge, non-discharge, and bending, thereby improving detection precision without requiring complex additional equipment.
2Measurement precision
If a larger amount of liquid is discharged per unit area to form the test pattern, then the detection accuracy of nozzle abnormalities improves, but the liquid consumption increases
Solution Approach 1:
The patent applies local quality by discharging different amounts of liquid for different purposes: a first liquid at a first discharge amount for general test pattern formation, and a second liquid at a second discharge amount (larger than the first) specifically for enhancing abnormality detection in critical areas. This localized variation in discharge amount improves detection accuracy while minimizing overall liquid consumption compared to uniformly discharging large amounts across the entire test pattern.
3Measurement precision
If multiple liquids are discharged with different discharge amounts, then the detection capability of nozzle abnormalities is enhanced, but the operation complexity increases
Solution Approach 1:
The patent applies universality by designing the liquid discharge apparatus to perform multiple functions: it can discharge both the first liquid and the second liquid using the same nozzle system, and the same apparatus handles both test pattern formation and abnormality detection. This multi-functionality enhances detection capability while avoiding the need for separate specialized equipment, thereby limiting the increase in operational complexity.
Data Source
AI summary
A liquid discharge apparatus includes: a liquid discharger to discharge a liquid from a nozzle; an imaging unit to capture a test pattern on a detection target member to acquire a test pattern image of the test pattern; circuitry configured to: cause the liquid discharger to discharge a first amount of the liquid per unit area from the nozzle onto a target object; cause the liquid discharger to discharge a second amount of the liquid per unit area larger than the first amount from the nozzle onto a detection target member to form the test pattern on the detection target member; perform image processing on the test pattern image on the detection target member acquired by the imaging unit; and determine presence or absence of abnormality in the nozzle based on the test pattern image obtained by the image processing.