Print Head Nozzle Condition Evaluation via External DBD Testing
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Solution Overview
Problem
Inkjet printers face challenges in maintaining print quality due to nozzle defects and blockages, which are difficult to detect and address in a timely and cost-effective manner, requiring complex and space-intensive circuitry for monitoring nozzle conditions.
Innovation Solution
The implementation of a Drive Bubble Detect (DBD) circuitry within the print head to perform tests on nozzles, processing results outside the print head, optimizing cost and space by using a test result register and result-ready register to store and process DBD test results efficiently, allowing for timely detection and replacement of faulty nozzles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex circuitry is used to monitor nozzle conditions, then detection accuracy is improved, but device complexity and space requirements increase
Solution Approach 1:
The patent extracts the complex processing and storage functions from the print head circuitry and relocates them to an external controller. The print head retains only essential monitoring components, while the controller handles DBD test execution, result processing, and nozzle condition determination. This extraction reduces print head complexity while maintaining detection accuracy.
Solution Approach 2:
The patent introduces an intermediary communication interface between the print head and external controller. This intermediary layer allows the print head to perform simple local measurements while the controller handles complex analysis, effectively mediating between the sensing element and the processing system to resolve the complexity contradiction.
2Reliability
If more monitoring resources are allocated within the print head, then nozzle detection capability is improved, but space and cost increase
Solution Approach 1:
The patent extracts resource-intensive functions (processing, storage, control logic) from the print head and places them in the external controller. This allows the print head to maintain reliable monitoring capability with minimal onboard resources, effectively resolving the contradiction between monitoring reliability and space constraints.
Solution Approach 2:
The patent shifts the monitoring resources from the spatial dimension (within the print head) to the external dimension (controller system). By moving resources to another dimension, the system achieves comprehensive monitoring capability without increasing print head space requirements.
3Manufacturing precision
If comprehensive nozzle testing is performed, then print quality is improved, but time consumption increases
Solution Approach 1:
The patent implements preliminary nozzle condition assessment through DBD tests that can be performed quickly to identify potentially faulty nozzles before actual printing. This preliminary action allows for early detection and replacement of defective nozzles, ensuring print quality without requiring extensive testing time during production.
Solution Approach 2:
The patent establishes a feedback mechanism where DBD test results are continuously monitored and used to determine nozzle condition. This feedback loop enables rapid identification of nozzle issues and triggers appropriate actions (replacement or adjustment), maintaining print quality while minimizing time loss through targeted rather than comprehensive testing.
Data Source
AI summary
In some examples, a print head includes a plurality of nozzles, a test result register to store a drive bubble detect (DBD) test result for a first nozzle of the plurality of nozzles, and a result-ready register to store a status indication set to a predetermined value provided responsive to storing of the DBD test result in the test result register, where the test result register and the result-ready register are accessible by a control unit outside the print head to evaluate a nozzle condition based on the DBD test result in the test result register.