Continuous Inkjet Print Head Imaging for Electrode Contamination Detection

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Solution Overview

Problem

Existing inkjet printer technologies struggle to detect ink contamination on components other than the gutter, such as charging and deflection electrodes, leading to potential printing failures.

Innovation Solution

A contamination detection device equipped with a camera that captures images from specific angles to detect ink contamination on a wider range of print head components, including a processing unit to analyze image data and predict contamination growth, allowing for automatic detection and timely cleaning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If laser light measurement is used to detect contamination, then contamination detection is possible, but the detection range is limited to gutter portion only

Engineering Contradiction:

Improvecontamination detection capabilityVSAvoiddetection range

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces the laser light measurement system with a camera-based imaging system. The camera captures images of the print head interior, and image processing algorithms analyze these images to detect contamination. This substitution enables detection across multiple components (gutter, charging electrodes, deflection electrodes) rather than being limited to the gutter portion, thereby expanding the detection range while maintaining contamination detection capability.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If operator manually checks contamination by removing cover, then contamination can be visually inspected, but the operation is complex and time-consuming

Engineering Contradiction:

Improvecontamination detection accuracyVSAvoidinspection operation simplicity

Core Design Contradiction:

Measurement precisionVSEase of operation

Solution Approach 1:

The system implements automatic contamination detection through a camera and image processing unit that continuously or periodically captures images and analyzes them for contamination without requiring operator intervention. The detection unit automatically compares image data, identifies contamination patterns, and can trigger cleaning operations, enabling the system to monitor and maintain itself without manual inspection.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

The manual visual inspection process is replaced by an automated optical imaging and image processing system. The camera captures images of the print head interior components, and software algorithms automatically analyze these images to detect contamination, eliminating the need for operators to manually remove covers and visually inspect components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Reliability

If comprehensive contamination detection is implemented, then printing failures can be prevented, but the device complexity increases

Engineering Contradiction:

Improveprinting operation reliabilityVSAvoiddetection system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The camera-based detection system serves multiple functions: it detects contamination on the gutter, charging electrodes, and deflection electrodes using the same hardware platform. The image processing unit analyzes different regions of the captured images to identify contamination patterns across various components, providing comprehensive monitoring through a unified multi-functional system rather than separate detection devices for each component.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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

Enables comprehensive detection of ink contamination across various print head components, preventing printing failures by identifying and predicting contamination growth, thereby reducing operational downtime.

Implementation Method 1

a camera that captures images from a side in a direction in which the ink droplets are ejected from the nozzle

Methodology Applied

Scientific EffectLight absorption and scattering: Absorption (EM radiation)

Data Source

PatentUS20250381777A1Print head equipped with contamination detection device and contamination detection device

Publication Date: 2025.12.18 KISHU GIKEN KOGYO CO LTD

AI summary

A print head equipped with a contamination detection device detects ink contamination of a print head of a continuous-type inkjet printer and includes a print head that includes a nozzle that ejects ink droplets, charging electrodes that charge the ink droplets, deflection electrodes that deflect the charged ink droplets with an electric field, and a gutter that collects the ink droplets that are not used for printing, and a contamination detection device that includes a camera that images at least a part of a flight region where the ink droplets ejected from the nozzle fly from a side in a direction in which the ink droplets are ejected from the nozzle or in a direction in which the deflection electrodes face each other, and an information processing unit that performs processing of image data captured by the camera.