Liquid Discharge Apparatus Nozzle Overlap Management
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Solution Overview
Problem
Existing liquid discharge apparatuses face issues with image quality degradation due to nozzle overlap, resulting in density unevenness and streaks caused by variations in discharge properties and positional deviations between adjacent heads.
Innovation Solution
A liquid discharge apparatus with multiple heads and a discharge control unit that forms a vertically striped mask pattern, selectively using or disabling nozzles in overlapping regions to align pixel data in parallel and intersecting directions, reducing nozzle usage rates and avoiding nozzles affected by airflow.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If multiple liquid discharge heads are arranged adjacent to each other to increase productivity, then the output or effective yield per time is improved, but density unevenness and streaks occur in the overlapping region due to nozzle overlap and positional deviations
Solution Approach 1:
The patent extracts and eliminates the problematic overlapping nozzles from the discharge operation. By identifying nozzles in the overlapping region and selectively disabling them based on discharge frequency analysis, the invention removes the source of density unevenness while preserving the productivity benefits of multiple adjacent heads
Solution Approach 2:
The patent applies different discharge strategies to different regions of the nozzle arrays. Nozzles in overlapping regions are treated differently from non-overlapping nozzles, with local adjustments to discharge frequency and selection based on the specific positional relationship and discharge characteristics of each nozzle group
2Productivity
If nozzles in overlapping regions are used to maintain full productivity, then the output per time is improved, but discharge property variations cause streaks and density unevenness
Solution Approach 1:
The patent implements a feedback mechanism by analyzing the discharge frequencies of individual nozzles and using this information to make intelligent selection decisions. The system monitors discharge properties and adjusts nozzle usage accordingly, prioritizing nozzles with more stable discharge characteristics while suppressing those prone to causing streaks
Solution Approach 2:
The patent changes the operational parameters of nozzles in overlapping regions by adjusting their discharge frequencies and selection probabilities. By modifying these parameters based on measured discharge properties, the system maintains productivity while ensuring consistent and reliable discharge performance
3Productivity
If all nozzles are operated at full capacity to maximize productivity, then the output per time is improved, but positional deviations between heads create image quality defects
Solution Approach 1:
The patent applies partial action by selectively operating only the necessary subset of nozzles rather than all nozzles at full capacity. By disabling certain nozzles in overlapping regions where positional deviations cause problems, the system achieves adequate productivity while eliminating image quality defects caused by misalignment
Data Source
AI summary
A liquid discharge apparatus includes multiple heads and circuitry. The multiple heads include a first head having a first nozzle array and a second head having a second nozzle array. The first nozzle array has first overlapped nozzles in one end in an array direction. The second nozzle array has second overlapped nozzles in another end in the array direction. The second overlapped nozzles are overlapped with the first overlapped nozzles in an overlapping region in the array direction. The circuitry causes the multiple heads to discharge liquid droplets to form mask pattern having both of first pixels and second pixels arrayed in the array direction in the overlapping region and intersecting pixels having either the first pixels or the second pixels arrayed in an intersecting direction intersecting the array direction in the overlapping region.