Thermal Printer Dot Density Control for Power and Quality
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Solution Overview
Problem
Thermal label printers face limitations in instantaneous maximum power consumption, leading to restrictions on the number of black-colored dots per line, which results in reduced printing speed and uneven print quality due to streaky noise, affecting the aesthetic appearance of labels.
Innovation Solution
A non-transitory computer-readable medium storing a printing processing program that generates a binarized dot pattern and applies a density reduction process to print lines with high black proportions, allowing for uniform printing speed without compromising print quality by selectively reducing the density of dots in specified groups.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If the label feeding speed is reduced for lines with high black proportion, then the instantaneous maximum power consumption is controlled within allowable limits, but the overall printing speed is reduced
Solution Approach 1:
The patent applies different dot densities to different regions within the same print line. Specifically, it identifies continuous dot groups (where dots are adjacent without gaps) and reduces their density, while maintaining normal density for non-continuous dot groups. This local differentiation allows the system to control peak power consumption in high-black-proportion areas without reducing the overall printing speed, as only specific dot groups within each line are affected.
Solution Approach 2:
The patent segments the dots in each print line into different groups based on their continuity characteristics. By identifying continuous dot groups separately from non-continuous dot groups, the system can apply selective density reduction only to the continuous groups that cause excessive power consumption, rather than reducing density across the entire line. This segmentation enables precise control over power consumption while preserving printing speed.
2Use of energy by moving object
If the label feeding speed is varied by line, then the power consumption is controlled, but streaky noise appears parallel to the main scanning direction and print uniformity is deteriorated
Solution Approach 1:
Instead of varying the label feeding speed by line (which causes visible streaks), the patent varies the dot density locally within each line. It identifies continuous dot groups and reduces their density while keeping the feeding speed constant throughout the printing process. This local quality adjustment eliminates the streaky noise caused by speed variations while still controlling power consumption within allowable limits.
3Use of energy by moving object
If the number of black-colored dots per line is restricted, then the power consumption is controlled, but the printing speed is reduced
Solution Approach 1:
The patent maintains the original printing speed by applying dot density reduction only to continuous dot groups within each line, rather than reducing the overall number of dots or slowing down the printing process. This localized approach controls power consumption by reducing the thermal load in high-density areas while preserving the printing speed through selective rather than universal dot reduction.
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
The solution maintains printing speed while preventing deterioration in print quality by reducing density only in high-black-proportion areas, thereby suppressing unevenness and ensuring consistent aesthetic appearance.
Implementation Method 1
a thermal line head that includes a plurality of heat generation elements and is configured to form dots on respective print lines
Data Source
AI summary
The disclosure discloses a non-transitory computer-readable medium storing a printing processing program for executing steps. In a line specification step, it is determined whether or not an on-dot ratio or the number of on-dots is equal to or greater than a threshold value and at least one print lines equal to or greater than a threshold value is specified. In a labeling step, a plurality of dot groups is identified such that on-dots adjacent to each other form one dot group. In a dot group specification step, at least one first dot groups including the at least one print lines is specified. In a density reduction process step, a density at the time of print formation of the on-dots included in the first dot groups is made lower than a density at the time of print formation of the on-dots included in at least one second dot groups.