Inkjet Printhead Out-of-Phase Firing Modulates Peak Power
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Solution Overview
Problem
Inkjet printers face challenges with fluctuating peak power requirements and visual effects of dead or malfunctioning nozzles, which are difficult to manage with existing technologies, leading to inefficiencies in power supply design and print quality.
Innovation Solution
The method involves configuring inkjet printheads with sets of nozzles that can print dots onto the same position, allowing for selective firing to modulate peak power requirements and using redundant nozzle rows to reduce visual effects of dead nozzles, achieved through out-of-phase printing and dot-at-a-time redundancy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If all nozzles fire simultaneously to maximize printing speed, then productivity is improved, but peak power requirement increases causing power supply instability
Solution Approach 1:
The printhead is divided into multiple independently controllable nozzle groups (first nozzles and second nozzles). Instead of firing all nozzles simultaneously, the invention segments the firing sequence into different time phases, with first nozzles firing during one phase and second nozzles firing during another phase. This segmentation allows the printing process to maintain high productivity while distributing power consumption over time, thereby reducing peak power requirements and stabilizing power supply demands.
2Reliability
If redundant nozzle rows are added to compensate for dead nozzles, then reliability is improved, but device complexity increases
Solution Approach 1:
The redundant nozzle rows are designed to serve multiple functions: they act as backup nozzles to compensate for dead or malfunctioning nozzles, and simultaneously function as active printing nozzles during their designated firing phases. The out-of-phase firing mechanism allows both first and second nozzle rows to contribute to the same print line, maximizing the utilization of redundant nozzles while maintaining print quality consistency. This multi-functional design reduces the need for additional dedicated backup nozzles, thereby limiting the increase in device complexity.
3Ease of manufacture
If out-of-phase firing is implemented to reduce peak power, then power supply design is simplified, but printing process complexity increases
Solution Approach 1:
The invention implements periodic action through out-of-phase firing sequences, where first nozzles and second nozzles are fired in alternating phases rather than simultaneously. This periodic firing pattern creates a rhythm in power consumption that reduces peak power requirements and simplifies power supply design. The controller is programmed with predetermined firing sequences that systematically alternate between first and second nozzle groups, transforming a complex power management problem into a manageable periodic control scheme.
Data Source
AI summary
A printhead system comprising an inkjet printhead and a printer controller for supplying dot data to the printhead is provided. The printhead comprises a plurality of transversely aligned color channels, each color channel comprising at least one nozzle row extending longitudinally along said printhead. Each nozzle in a color channel ejects the same colored ink. The printhead is comprised of a plurality of printhead modules with each printhead module comprising a respective segment of each nozzle row. The printer controller is programmed to supply dot data such that each of the printhead modules fires a respective segment within a predetermined segment-time. At least one of the fired segments is contained in a different color channel from at least one other of the fired segments.