Inkjet Recording Apparatus Waste Ink Estimation
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Solution Overview
Problem
Existing inkjet recording apparatuses face challenges in accurately estimating the amount of waste ink ejected outside the recording medium during full-surface recording, leading to potential ink overflow and contamination, due to complex and costly measurement systems or inaccurate calculations based on predetermined values.
Innovation Solution
A recording apparatus and method that divides the print buffer into segments, counts recording data on a segment-by-segment basis, selects segments not corresponding to the recording medium, and calculates the cumulative amount of waste ink ejected, allowing for accurate estimation without complex mechanisms, using a simple data processing structure.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a platen absorber is used to absorb ink ejected outside the recording medium during full-surface recording, then ink overflow and platen contamination are prevented, but the absorber reaches its capacity limit and requires complex measurement systems to monitor waste ink accumulation
Solution Approach 1:
The patent replaces complex mechanical measurement systems with a computational approach. The control unit calculates waste ink volume by processing recording data to determine the number of dots ejected in borderless areas, multiplying by the volume per dot. This substitution of mechanical sensing with data-based calculation resolves the contradiction by maintaining reliable waste ink monitoring without requiring complex physical measurement devices.
Solution Approach 2:
The patent creates a virtual model of waste ink accumulation through data processing. Instead of physically measuring ink in the absorber, the system creates a digital representation by calculating dot counts from recording data and estimating corresponding ink volumes. This virtual copy allows accurate monitoring of waste ink levels without physical sensors, resolving the contradiction between reliability and device complexity.
2Device complexity
If predetermined values are used to calculate waste ink amount, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent transitions from static predetermined values to dynamic calculation based on actual recording conditions. The control unit processes recording data to determine the number of dots ejected in borderless areas for each specific recording operation, then calculates waste ink volume accordingly. This dynamic approach adapts to varying recording conditions (different media sizes, resolutions, dot patterns), maintaining high measurement precision while keeping the device simple by using only data processing.
3Manufacturing precision
If the number of scans on the same area is increased to adjust image quality, then image quality improves, but the amount of waste ink increases requiring more frequent monitoring
Solution Approach 1:
The patent implements a feedback mechanism where the control unit continuously calculates waste ink volume based on recording data and compares it against the platen absorber's capacity. When multiple scans are performed to improve image quality, the system accumulates waste ink calculations for each scan, providing real-time feedback on total waste ink accumulation. This allows the system to monitor and manage waste ink levels even when image quality is enhanced through repeated scanning.
Data Source
AI summary
A print buffer for storing recording data is divided into a plurality of segments and the amount of recording data causing a recording head to perform a recording operation is counted on a segment-by-segment basis. A recording medium is compared to the print buffer with respect to a scanning direction of the recording head and segments not corresponding to the inside of the recording medium are selected from the plurality of segments. The amount of recording data included in the selected segments and causing a recording operation to occur is counted and added up to estimate the amount of ink ejected outside the recording medium.