Segmented Nozzle Array Inkjet Recording Edge Control
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Solution Overview
Problem
Conventional image recording apparatuses face challenges in efficiently recording images up to the edge of a recording medium without wasting ink or causing stains, and they often have high costs and low reliability due to the use of long nozzle arrays.
Innovation Solution
An image recording apparatus with a carrier mechanism, recording units composed of nozzle arrays, and a detection unit that controls the nozzles based on image data and detection information to inject ink only within the edges of the recording medium, ensuring edge-to-edge recording without waste.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a long nozzle array (line head) is used to record images across the entire recording medium, then the recording process can be applied rapidly without carriage movement, but the device becomes expensive with low yield and low reliability
Solution Approach 1:
The patent divides the recording system into multiple short nozzle arrays arranged in the sub-scanning direction, each handling a portion of the recording medium width. This segmentation allows the use of reliable short nozzle arrays while maintaining full-width coverage through coordinated operation of multiple segments, resolving the contradiction between recording speed and device reliability.
2Productivity
If a long nozzle array (line head) is used to record images across the entire recording medium, then the recording process can be applied rapidly without carriage movement, but the manufacturing cost increases and yield decreases
Solution Approach 1:
The patent segments the nozzle array into multiple short arrays arranged in the sub-scanning direction. This allows manufacturing of cheaper, more reliable short nozzle arrays instead of expensive long line heads, while maintaining rapid recording capability through coordinated operation of multiple segments, thus resolving the contradiction between productivity and ease of manufacture.
3Area of stationary object
If ink is injected across the entire nozzle array area, then complete coverage is achieved, but ink is wasted and stains occur outside the recording medium
Solution Approach 1:
The patent applies local quality control by independently controlling the ink ejection of each short nozzle array based on the detected position and size of the recording medium. This allows ink to be injected only where needed on the recording medium, achieving complete coverage while preventing waste and stains outside the medium boundaries.
Solution Approach 2:
The patent uses feedback from the recording medium detection unit to control the ink ejection of each nozzle array. The detection information about medium position and size is fed back to adjust the ejection timing and range of each short nozzle array, ensuring ink is deposited only within the medium boundaries and eliminating waste.
Data Source
AI summary
A recording medium detection unit is provided on the upper stream side of a carrier mechanism in a carrier route and detects at least the front and back ends in a carrier direction of a recording medium. A nozzle array control unit controls the drive of a plurality of nozzles on the basis of job information reported by a higher-order device and the detection information of the front and back ends by the recording medium detection unit and enables the plurality of nozzles to perform a recording process for inject ink only an area in the range between the front and back ends of the recording medium. A control unit receives image data and also notifies the higher-order device of the stoppage of image data transfer according to the detection of the back end of the recording medium by the recording medium detection unit.