Localized Printhead Cleaning Using Nozzle Degradation Metrics
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Solution Overview
Problem
Conventional printhead cleaning methods in printing systems apply uniform cleaning intensity across the entire printhead, leading to over-cleaning of some nozzles, under-cleaning of others, and inefficiencies in resource and time consumption, which affects print quality and increases maintenance costs.
Innovation Solution
A localized printhead cleaning approach that includes a printhead health check to identify nozzle defects, determine nozzle degradation metrics, and adjust parameters such as carrier speed, motion profile, vacuum level, and wiper pressure for targeted cleaning based on the specific condition of each nozzle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If uniform cleaning intensity is applied across the entire printhead, then the cleaning process is simple and fast, but some nozzles are over-cleaned while others are under-cleaned, affecting print quality
Solution Approach 1:
The patent implements localized cleaning by adjusting cleaning parameters (vacuum level, wiper pressure, carrier speed) based on the specific condition of each nozzle or nozzle group. The system identifies defective nozzles through health checks and applies customized cleaning actions to each location, ensuring that cleaning intensity matches the actual contamination level of each nozzle rather than applying uniform cleaning across the entire printhead.
2Ease of operation
If uniform cleaning parameters are used for all nozzles, then the cleaning process is easy to control, but resource consumption increases and downtime is extended due to inefficiency
Solution Approach 1:
The patent segments the cleaning process into distinct phases: health check identification of defective nozzles, localized cleaning parameter adjustment for specific nozzle groups or individuals, and targeted cleaning execution. This segmentation allows the system to focus resources only on nozzles that require cleaning, avoiding waste of cleaning materials, time, and energy on already functional nozzles.
3Reliability
If aggressive cleaning is applied to all nozzles, then clogged nozzles may be cleared, but printhead lifespan is reduced due to excessive wear
Solution Approach 1:
The patent applies partial cleaning action by adjusting cleaning parameters according to the actual condition of each nozzle. For nozzles with minor clogs, gentler cleaning is applied; for severely clogged nozzles, more intensive cleaning is used. This prevents excessive wear on nozzles that don't require aggressive cleaning while still effectively clearing problematic nozzles, thereby extending printhead lifespan.
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
Improves print quality by ensuring all nozzles are adequately cleaned, extends printhead lifespan, reduces maintenance costs, and enhances the efficiency and productivity of the printing system by minimizing resource consumption and downtime.
Implementation Method 1
detect nozzle outs using a laser emitter-receiver pair of the carrier and identify interruptions in the expected trajectory of jetted drops from the nozzles
Implementation Method 2
Move the carrier with the adjusted at least one parameter to across the printhead. The adjusted parameter can include adjusting a vacuum level of cleaning devices
Implementation Method 3
The adjusted parameter can include adjusting a contact pressure of wipers equipped on the carrier to remove material from a plate surface of one or more printer nozzles
Data Source
AI summary
Apparatuses, methods, and systems for localized printhead cleaning of a printing system are disclosed. A printing system performs a printhead health check operation for a printhead of the printing system. The printhead health check operation includes identifying and recording a set of nozzle defects within the printhead's nozzles, which can include any of clogs, misfires, and inconsistencies. Based on the printhead health check operation, the printing system determines a set of nozzle degradation metric values for the printhead, indicating the extent and nature of the nozzle defects. Using the set of nozzle degradation metric values, the printing system generates a set of actions for a carrier associated with the printhead. The set of actions adjusts at least one parameter of the cleaning device, such as its speed, motion profile, vacuum level, or wiper pressure, and defines a printhead actuation strategy. The printing system performs the cleaning of the printhead in accordance with the generated actions.