Printer Ink Nozzle Flushing Strategy for Quality Throughput Balance

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Solution Overview

Problem

Printers that eject ink from nozzles face clogging issues due to moisture evaporation and increased ink viscosity, leading to reduced throughput and print quality, as existing flushing methods either compromise print quality or throughput.

Innovation Solution

A printer and printing method that combine regular flushing into a maintenance unit with onto-paper flushing, allowing for adjustable flushing conditions based on print mode and resolution to balance throughput and print quality, using a printhead with ink nozzles, a maintenance unit, a head moving mechanism, and a parameter decision unit to determine optimal flushing conditions.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If regular flushing is performed to prevent ink nozzle clogging, then print quality is maintained, but throughput decreases due to printhead movement to maintenance unit

Engineering Contradiction:

Improveprint qualityVSAvoidthroughput

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent implements dynamic flushing strategy where the system adaptively selects between regular flushing and onto-paper flushing based on real-time printing conditions, print mode, and nozzle usage patterns. This dynamic approach allows the system to optimize between print quality and throughput by choosing the appropriate flushing method for each specific situation, rather than using a fixed flushing schedule

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent enables onto-paper flushing where the printing process itself serves the dual purpose of producing output and flushing the nozzles. The printing operation generates flush dots on the paper that simultaneously clear the nozzles, making the printing process self-servicing for maintenance needs without requiring separate flushing operations

Inventive Principle:

Principle #25Self-service

2Productivity

If onto-paper flushing is used to maintain throughput, then printing continues without interruption, but print quality deteriorates due to flush dots on paper

Engineering Contradiction:

ImprovethroughputVSAvoidprint quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The patent applies local quality by selectively applying flush dots only to specific regions or patterns on the paper that are less visually critical, and by controlling the density and distribution of flush dots based on the print mode. In photo modes where quality is paramount, flush dots are minimized or placed in imperceptible areas, while in draft modes they can be more prominent

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The system dynamically adjusts the flushing strategy based on the selected print mode (photo, presentation, draft, etc.), balancing the visibility of flush dots against throughput requirements for each mode

Inventive Principle:

Principle #15Dynamics

3Reliability

If flushing frequency is increased to prevent nozzle clogging, then nozzle reliability improves, but ink consumption increases

Engineering Contradiction:

Improvenozzle ejection reliabilityVSAvoidink consumption

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent implements feedback-based flushing control where the system monitors nozzle usage patterns, time since last ejection, and printing conditions to determine when flushing is actually needed. This feedback mechanism prevents unnecessary flushing operations, reducing ink consumption while maintaining nozzle reliability by flushing only when clogging risk is detected

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The system changes flushing parameters (frequency, intensity, target location) based on varying conditions such as print mode, environmental temperature, humidity, and observed nozzle performance, optimizing the balance between reliability and ink consumption for each specific operating context

Inventive Principle:

Principle #35Parameter changes

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 effectively suppresses ink nozzle ejection problems while balancing print quality and throughput by combining flushing operations that do not lower print quality or throughput, allowing for prioritization based on print mode and conditions.

Implementation Method 1

A piezoelectric device 22 for changing shape in response to an applied voltage is built into each ink nozzle 25

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

the ink nozzles 25 have a piezoelectric device 22 for changing shape in response to an applied voltage built into each ink nozzle 25 and eject ink in the form of ink droplets 26

Methodology Applied

Scientific EffectPiezoelectric actuation: Piezoelectric Effect

Implementation Method 3

the ink nozzles can become clogged as a result of moisture evaporating from the ends of the nozzles and ink viscosity increasing

Methodology Applied

Scientific EffectEvaporation: Evaporation

Data Source

PatentUS9895893B2Printer and printing method

Publication Date: 2018.02.20 SEIKO EPSON CORP

AI summary

A control unit 6 of a printer 1 determines the combination of conditions of regular flushing that ejects ink into a maintenance unit 5, and onto-paper flushing that ejects ink onto printing paper P, based on the set print mode. To achieve the dot density defined by the selected combination, flushing dots Df are added to the input data 10 to be printed and are printed. When printing, regular flushing is executed at the frequency and strength determined by the selected combination of conditions.