Printer Protrusion Roller Mark Suppression via Variable Force
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Solution Overview
Problem
Conventional printers face issues with recording quality due to protrusion marks from grip rollers during duplex printing, leading to inconsistent results and increased printer size and complexity in attempts to mitigate these issues.
Innovation Solution
A printer that uses a pseudo recorded image data producing unit to correct pixel densities based on the arrangement pattern of protrusions on the grip roller, allowing for controlled recording on both surfaces of a medium while minimizing the impact of protrusion marks, and includes a conveying unit with a protrusion roller to manage the recording medium effectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a grip roller with protrusions is used to hold the recording medium, then displacement of recording positions is prevented, but protrusion marks are left on the recording surface degrading sublimation dye transfer
Solution Approach 1:
The patent applies preliminary action by adjusting the pressing force of the grip roller before the sublimation transfer process. The pressing force is set to a first value during the grip roller contact phase to prevent displacement, then changed to a second value before thermal transfer to eliminate protrusion marks, ensuring both positioning accuracy and surface quality
Solution Approach 2:
The patent implements dynamics by making the pressing force of the grip roller variable rather than constant. The pressing force changes based on the operational phase: a higher force during positioning and a lower force during transfer, allowing the system to adapt to different functional requirements and resolve the contradiction between positioning and surface quality
2Object-affected harmful factors
If the pressing force between grip roller and pinch roller is adjusted to prevent protrusion marks, then recording quality improves, but the grip roller cannot effectively hold the recording medium
Solution Approach 1:
The patent uses dynamics by implementing time-variant pressing force control. The pressing force is dynamically adjusted between a first value (higher) for reliable holding and a second value (lower) for mark prevention, with the transition timed to occur before the thermal transfer process begins, thus maintaining both holding reliability and recording quality
Solution Approach 2:
The patent applies preliminary action by pre-adjusting the pressing force to a lower second value before the thermal transfer process starts. This preliminary adjustment ensures that when the transfer occurs, the grip roller pressing force will not create protrusion marks, while the holding capability was already established during the earlier high-force phase
3Object-affected harmful factors
If the path length between printing head and grip roller is increased to prevent contact marks, then recording quality is improved, but the printer size increases
Solution Approach 1:
The patent replaces the mechanical solution (increasing path length to avoid contact) with a control system solution (varying pressing force). By using automated pressing force adjustment based on operational phase, the system eliminates protrusion marks without requiring additional physical space, thus maintaining compact printer dimensions while achieving the desired quality improvement
4Object-affected harmful factors
If a mechanism to press and heat the recording medium is added to smooth protrusion marks, then recording quality is improved, but the printer structure becomes complicated and larger
Solution Approach 1:
The patent replaces the complex mechanical smoothing mechanism with a simpler control-based approach. By varying the pressing force of existing components (grip roller and pinch roller) according to the operational phase, the system achieves mark prevention without requiring additional pressing/heating mechanisms, thus reducing structural complexity while maintaining recording quality
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 solution ensures consistent recording quality on both surfaces of the medium, reducing the visibility of protrusion marks and maintaining a compact printer design without increasing complexity.
Implementation Method 1
a conveying unit that using a protrusion roller having thereon protrusions protruding toward an outer periphery and abutting a first surface of the recording medium, conveys the recording medium
Implementation Method 2
a recording operation under a sublimation transfer scheme in which a sublimation dye (sublimation pigment) included in an ink layer of an ink ribbon is transferred onto a recording layer of a recording medium
Data Source
AI summary
A printer includes a recording unit that executes on a recording medium, a recording operation under a sublimation transfer scheme; a conveying unit that using a protrusion roller having protrusions protruding toward an outer periphery and abutting a first surface of the recording medium, conveys the recording medium to a recording position for the recording operation; a pseudo recorded image data producing unit that produces pseudo recorded image data that includes pseudo pixels obtained by correcting a density of each predetermined pixel that is determined corresponding to an arrangement pattern of the protrusions on the protrusion roller and is determined from among pixels to be recorded in a second area that excludes a first area that is in contact with the protrusions, on the first surface of the conveyed recording medium; and a recording control unit that controls the recording unit based on the pseudo recorded image data.