Ink-jet Nozzle Thickening Detection and Selective Waveform Control
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Solution Overview
Problem
Ink-jet printers using quick-drying ink face issues with ink thickening in nozzles, leading to ejection delays and image quality deterioration due to infrequent use of certain nozzles, which are not effectively addressed by existing flushing methods.
Innovation Solution
An ink-jet recording apparatus equipped with a conveyance mechanism, waveform signal output circuit, continuous non-ejection counter, ejection history memory, non-ejection frequency detector, thickening degree determiner, and waveform signal selector to detect non-ejection frequencies and thickening degrees in nozzles, and apply appropriate flushing or increased ejection energy to prevent ink thickening.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If quick-drying ink is used to shorten printing cycle and increase printing speed, then productivity is improved, but ink thickening in nozzles occurs leading to ejection failures and reliability deteriorates
Solution Approach 1:
The system performs preliminary detection of non-ejection patterns and proactively applies flushing operations or waveform adjustments before ink thickening causes ejection failures. By monitoring nozzle usage patterns and predicting thickening risks, the system takes preventive action to maintain ink flowability and ensure reliable ejection performance.
Solution Approach 2:
The system continuously monitors ejection patterns, counts non-ejection cycles, and detects thickening trends to provide feedback for adjusting flushing frequency and waveform parameters. This closed-loop control ensures that preventive measures are dynamically adapted to actual nozzle conditions, maintaining optimal ejection performance while using quick-drying ink.
2Reliability
If flushing ejection is performed in region outside print region to prevent ink thickening, then reliability is improved, but loss of substance increases due to ink consumption
Solution Approach 1:
Instead of uniform flushing across all nozzles, the system applies flushing operations selectively only to nozzles exhibiting non-ejection patterns or thickening risks. By localizing the flushing action to specific problematic nozzles based on detected usage patterns, the system prevents ink waste while maintaining ejection reliability where needed.
Solution Approach 2:
The system adjusts flushing parameters such as waveform amplitude, duration, and frequency based on detected thickening degrees and non-ejection patterns. By optimizing these parameters, the system achieves effective ink renewal with minimal ink consumption, balancing reliability improvement against substance loss.
3Reliability
If non-ejection flushing is performed frequently to prevent ink thickening, then reliability is improved, but use of energy increases
Solution Approach 1:
The system implements periodic flushing operations based on detected non-ejection patterns and thickening risks, rather than continuous flushing. By timing flushing operations to coincide with detected needs and using periodic waveform applications, the system maintains ejection reliability while minimizing unnecessary energy consumption during normal operation.
Solution Approach 2:
The system applies flushing energy selectively and partially - using increased waveform amplitude or extended duration only when thickening is detected, rather than applying full flushing energy continuously. This partial action approach maintains reliability when needed while reducing overall energy consumption during normal ejection operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Accurately determines and mitigates ink thickening in nozzles, reducing ejection delays and ensuring high-quality image formation by selectively performing non-ejection flushing or adjusting ejection energy based on nozzle usage patterns.
Implementation Method 1
a piezoelectric sheet which extends over a plurality of pressure chambers, a plurality of individual electrodes which are opposed to the respective pressure chambers, and a common electrode which is opposed to the plurality of individual electrodes with the piezoelectric sheet sandwiched therebetween... a pulsed drive potential is applied to an individual electrode so that an electric field in a thickness direction of a piezoelectric layer acts on a portion of the piezoelectric sheet sandwiched between this individual electrode and the common electrode. As a result, in this portion, the piezoelectric sheet expands in the thickness direction.
Data Source
AI summary
A waveform signal output circuit selectively outputs, to an ejection energy applier, either one of a first waveform signal so as to make an ink droplet ejected from a nozzle and a second waveform signal so as not to make an ink droplet ejected from the nozzle. A continuous non-ejection counter counts a continuous non-ejection number. A ejection history memory stores therein an ejection history. A non-ejection frequency detector detects a non-ejection frequency. A thickening degree determiner determines a thickening degree of ink in the nozzle. A waveform signal selector makes the waveform signal output circuit output the second waveform signal to the ejection energy applier when an ink droplet is not ejected in the current printing cycle and in addition a thickening degree is equal to or greater than a predetermined value.