Printer Controller Printhead Nozzle Blockage Prevention
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Solution Overview
Problem
In Thermal Ink Jet (TIJ) printers, non-firing intervals due to nozzle blockages caused by ink evaporation lead to decap anomalies, resulting in gaps in printed lines, affecting the accuracy of printed plots or drawings.
Innovation Solution
Implementing a method to control printhead operations by using different print masks and operations for selected and non-selected features in an image, reducing the number of print operations per traversal for selected features, thereby minimizing nozzle usage and preventing blockages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the printhead performs multiple print operations per traversal to ensure complete coverage of all features, then the printing completeness is improved, but the time between nozzle firings increases causing ink evaporation and nozzle blockages
Solution Approach 1:
The patent divides the image features into two categories: selected features and non-selected features. Different print operation sequences are applied to each category, allowing the printhead to use optimized printing patterns for selected features that reduce the number of print operations and minimize the time between nozzle firings, thereby preventing ink evaporation and nozzle blockages while maintaining printing completeness
Solution Approach 2:
The patent applies different printing strategies to different parts of the image based on their importance. Selected features (such as text or critical graphical elements) receive specialized print operation sequences with reduced operations, while non-selected features use standard printing. This local differentiation allows the system to maintain overall printing completeness while protecting nozzle functionality for critical areas
2Reliability
If the number of print operations per traversal is reduced for selected features, then the time between nozzle firings decreases preventing ink evaporation, but the printing complexity increases due to mask management
Solution Approach 1:
The patent performs preliminary processing by creating and assigning print masks before the actual printing operation. The controller identifies selected features in advance and assigns appropriate print operation sequences to them. This preliminary action organizes the complexity upfront, allowing the printing process itself to proceed with simpler, more reliable nozzle operations that reduce evaporation risk
3Manufacturing precision
If different print operation sequences are used for selected and non-selected features, then the printing accuracy is improved, but the device complexity increases due to multiple mask types
Solution Approach 1:
The patent uses a universal mask data structure that can represent different print operation sequences. Rather than requiring entirely separate systems for different feature types, the mask system is designed to be multi-functional, accommodating both standard and reduced print operation sequences within a unified framework. This reduces device complexity while maintaining the ability to achieve high printing accuracy for selected features
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
This approach reduces the time between nozzle firings, decreases the likelihood of decap anomalies, and enhances the accuracy and reliability of printed plots by optimizing printhead usage and maintenance.
Implementation Method 1
a heating element arranged to heat the printing fluid rapidly so that printing fluid is ejected from a nozzle orifice
Implementation Method 2
heat the printing fluid rapidly so that printing fluid is ejected
Implementation Method 3
Evaporation of water contained in a printing fluid such as, for example, an ink, can create a plug in a nozzle orifice
Data Source
AI summary
Example implementations provide a controller for controlling printing of a printer, the controller comprising:an input interface for accessing an image to be printed;an image processor to identify at least one selected feature within the image; and circuitry:a. to control printing of said at least one selected feature using a respective print operation; andb. to control printing of said image, other said at least one selected feature, using a further respective print operation;c. said respective print operation being different to said further respective print operation.