IMAGE FORMING APPARATUS, IMAGE FORMING METHOD, AND STORAGE MEDIUM

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application is based on and claims priority pursuant to 35 U.S.C. § 119(a) to Japanese Patent Application Nos. 2021-057704, filed on Mar. 30, 2021 and 2021-179286, filed on Nov. 2, 2021, in the Japan Patent Office, the entire disclosure of each of which is hereby incorporated by reference herein.

BACKGROUND
Technical Field

Embodiments of the present disclosure relate to an image forming apparatus, an image forming method, and a storage medium for performing the image forming method.

Related Art

There is known an image forming apparatus including a liquid discharge head in which a plurality of nozzles is arranged in a sub-scanning direction as a nozzle row to discharge liquid. The liquid discharge head discharges the liquid while moving relative to a recording medium in a main scanning direction and the sub-scanning direction perpendicular to the main scanning direction to form an image on the recording medium.

SUMMARY

Embodiments of the present disclosure describe an improved image forming apparatus that includes a liquid discharge head, an irradiation unit, a carriage, and a moving unit. The liquid discharge head discharges a liquid onto a recording medium. The liquid includes a metallic ink and a color ink. The irradiation unit irradiates the liquid on the recording medium with light. The liquid discharge head and the irradiation unit are mounted on the carriage. The moving unit perform a main scanning movement in which the carriage is moved relative to the recording medium in a main scanning direction and a sub-scanning movement in which the carriage is moved relative to the recording medium in a sub-scanning direction perpendicular to the main scanning direction. The liquid discharge head discharges the metallic ink in a region of the recording medium in the main scanning movement and discharges the color ink in the region in which the metallic ink has been discharged, in the same main scanning movement in which the metallic ink is discharged. Thereafter, the irradiation unit irradiates the region in which the metallic ink and the color ink have been discharged, with the light in the same main scanning movement.

According to other embodiments of the present disclosure, there are provided an image forming method and a non-transitory storage medium storing program codes which, when executed by one or more processors, cause the one or more processors to perform the image forming method. The image forming method includes discharging a liquid onto a recording medium, irradiating the liquid on the recording medium with light, and performing a main scanning movement in which positions where the liquid is discharged and the light is emitted are moved relative to the recording medium in a main scanning direction and a sub-scanning movement in which the positions where the liquid is discharged and the light is emitted are moved relative to the recording medium in a sub-scanning direction perpendicular to the main scanning direction. The liquid includes a metallic ink and a color ink. The image forming method further includes discharging the metallic ink in a region of the recording medium in the main scanning movement, discharging the color ink in the region in which the metallic ink has been discharged, in the same main scanning movement in which the metallic ink is discharged, and irradiating the region in which the metallic ink and the color ink have been discharged, with the light in the same main scanning movement.

BRIEF DESCRIPTION OF THE DRAWINGS

A more complete appreciation of the disclosure and many of the attendant advantages and features thereof can be readily obtained and understood from the following detailed description with reference to the accompanying drawings, wherein:

FIG. 1A is a perspective front view of an image forming apparatus according to an embodiment of the present disclosure;

FIG. 1B is a perspective rear view of the image forming apparatus according to the present embodiment;

FIG. 2 is a plan view of a carriage according to the present embodiment;

FIG. 3 is a block diagram illustrating a configuration of hardware of the image forming apparatus according to the present embodiment;

FIG. 4 is a block diagram illustrating a functional configuration of a controller unit according to the present embodiment;

FIG. 5 is a flowchart illustrating an operation of the image forming apparatus according to the present embodiment;

FIGS. 6A to 6D are plan views of a sheet on which images are formed in first to fourth main scanning movements, respectively;

FIG. 7 is a perspective view illustrating another example of the configuration of the image forming apparatus according to the present embodiment; and

FIG. 8 is a plan view of a carriage according to another embodiment.

The accompanying drawings are intended to depict embodiments of the present disclosure and should not be interpreted to limit the scope thereof. The accompanying drawings are not to be considered as drawn to scale unless explicitly noted. In addition, identical or similar reference numerals designate identical or similar components throughout the several views.

DETAILED DESCRIPTION

In describing embodiments illustrated in the drawings, specific terminology is employed for the sake of clarity. However, the disclosure of this specification is not intended to be limited to the specific terminology so selected, and it is to be understood that each specific element includes all technical equivalents that have a similar function, operate in a similar manner, and achieve a similar result.

Referring now to the drawings, embodiments of the present disclosure are described below. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise.

Embodiments of the present disclosure are described below with reference to drawings. In each of the drawings, the same reference codes are allocated to components or portions having the same configuration, and redundant descriptions of the same components may be omitted.

Further, the embodiments described below are some examples of an image forming apparatus for embodying the technical idea of the present disclosure, and embodiments of the present disclosure are not limited to the embodiments described below. The dimensions, materials, and shapes of components, relative arrangements thereof, and the like described below are not intended to limit the scope of the present disclosure thereto but are intended to exemplify the present disclosure unless otherwise specified. The size, positional relation, and the like of components illustrated in the drawings may be exaggerated for clarity of description.

An image forming apparatus according to an embodiment of the present disclosure includes a liquid discharge head, an irradiation unit, a carriage, and a moving unit. The liquid discharge head discharges a liquid onto a recording medium. The irradiation unit irradiates the liquid on the recording medium with light. The liquid discharge head and the irradiation unit are mounted on the carriage. The moving unit performs a main scanning movement and a sub-scanning movement. In the main scanning movement, the carriage is moved relative to the recording medium in a main scanning direction. In the sub-scanning movement, the carriage is moved relative to the recording medium in a sub-scanning direction perpendicular to the main scanning direction.

The liquid includes a metallic ink and a color ink. The metallic ink and the color ink are, for example, ultraviolet curable, and the irradiation unit irradiates the liquid (e.g., the metallic ink and the color ink) with ultraviolet rays to cure the liquid.

In the present embodiment, the liquid discharge head discharges the metallic ink in a region of the recording medium in the main scanning movement. Then, the liquid discharge head discharges the color ink in the region in which the metallic ink has been discharged, in the same main scanning movement in which the metallic ink is discharged. The irradiation unit irradiates the region in which the metallic ink and the color ink have been discharged, with the light in the same main scanning movement.

As a result, a long time can be secured from the discharge of the metallic ink to the start of curing the metallic ink, and a colored and highly glossy image such as a metallic color image can be formed. Here, the term “metallic” refers to gloss like metal.

An inkjet image forming apparatus is described below as an example according to the present embodiment. The inkjet image forming apparatus discharges ultraviolet curable ink onto a sheet to form an image. Here, the ink is an example of liquid, and the sheet is an example of a recording medium. The sheet includes various types of paper such as plain paper and gloss paper. The recording medium is not limited to paper, and may be a plastic film, prepreg, silver foil, or the like.

Note that image formation, recording, printing, image printing, and print in the terms of the embodiments are synonymous. Further, the term “liquid” includes any liquid having a viscosity or a surface tension that can be discharged from the liquid discharge head. However, preferably, the viscosity of the liquid is not greater than 30 mPa·s under ordinary temperature and ordinary pressure or by heating or cooling.

Examples of the liquid include a solution, a suspension, or an emulsion including, for example, a solvent, such as water or an organic solvent, a colorant, such as dye or pigment, a functional material, such as a polymerizable compound, a resin, or a surfactant, a biocompatible material, such as DNA, amino acid, protein, or calcium, and an edible material, such as a natural colorant. Such a solution, a suspension, or an emulsion can be used for, e.g., inkjet ink; surface treatment liquid; a liquid for forming an electronic element component, a light-emitting element component, or an electronic circuit resist pattern; or a material solution for three-dimensional fabrication.

The “liquid discharge head” is a functional component that discharges and jets the liquid from the nozzle. Examples of an energy source for generating energy to discharge the liquid include a piezoelectric actuator (a laminated piezoelectric element or a thin-film piezoelectric element), a thermal actuator that employs a thermoelectric conversion element, such as a thermal resistor, and an electrostatic actuator including a diaphragm and opposed electrodes.

In the following description, a main scanning direction is defined as an X-axis direction, a sub-scanning direction substantially perpendicular to the main scanning direction is defined as a Y-axis direction, and a direction perpendicular to both the X-axis direction and the Y-axis direction is defined as a Z-axis direction. Note that a direction indicated by the arrow in the X-axis direction is referred to as +X direction, a direction opposite to +X direction is referred to as −X direction, a direction indicated by the arrow in the Y-axis direction is referred to as +Y direction, a direction opposite to +Y direction is referred to as −Y direction, a direction indicated by the arrow in the Z-axis direction is referred to as +Z direction, and a direction opposite to +Z direction is referred to as −Z direction. However, these directions do not limit the orientation of the image forming apparatus, and the image forming apparatus can be oriented in arbitrary direction.

First, an overall configuration of an image forming apparatus 10 according to a first embodiment of the present disclosure is described. FIGS. 1A and 1B are perspective views illustrating an example of the overall configuration of the image forming apparatus 10 according to the present embodiment. FIG. 1A is a perspective front view of the image forming apparatus 10, and FIG. 1B is a perspective rear view of the image forming apparatus 10.

The image forming apparatus 10 includes a carriage 200 and a sheet table 13 on which a sheet P is placed. An ink discharge head (e.g., a metallic ink discharge head 300 and color ink discharge heads 301a, 301b, 301c, and 301d as illustrated in FIG. 2) and an irradiation unit (e.g., irradiation units 400a and 400b as illustrated in FIG. 2) are mounted on the carriage 200. The ink discharge head is an example of a liquid discharge head including a nozzle row in which a plurality of nozzles is arranged in the sub-scanning direction to discharge ink onto the sheet P. The ink discharge head discharges ink from the nozzles to form an image. The nozzles face the sheet table 13. The irradiation unit also faces the sheet table 13. The ink discharge head and the irradiation unit is described in detail later with reference to FIG. 2.

A guide rod 19 is bridged between left and right side plates 18a and 18b. The guide rod 19 movably holds the carriage 200 in the X-axis direction. The carriage 200 moves in the main scanning direction relative to the sheet P along the guide rod 19 (i.e., a main scanning movement). The carriage 200, the guide rod 19, and the side plates 18a and 18b are combined as a single body and movable together in the Y-axis direction along a guide rail 29 disposed below the sheet table 13. The carriage 200 moves in the sub-scanning direction relative to the recording medium along the guide rail 29 (i.e., a sub-scanning movement). Further, the carriage 200 is movably held in the Z-axis direction (vertical direction).

The image forming apparatus 10 can perform so-called bidirectional printing in which an image is formed on each of a forward path which is the main scanning movement in +X direction (i.e., a forward main scanning movement) and a backward path which is the main scanning movement in the −X direction (i.e., a backward main scanning movement).

Next, a configuration of the carriage 200 is described with reference to FIG. 2. FIG. 2 is a plan view illustrating an example of the configuration of the carriage 200. In FIG. 2, the carriage 200 illustrated in FIG. 1 is viewed in +Z direction. The carriage 200 has a box shape that is open in −Z direction. As illustrated in FIG. 2, the carriage 200 includes, inside the box shape, the metallic ink discharge head 300, the color ink discharge heads 301a, 301b, 301c, and 301d, and the irradiation units 400a and 400b.

Note that the color ink discharge heads 301a, 301b, 301c, and 301d have the same configuration except for the color of ink to be discharged and the position where each of the color ink discharge heads 301a, 301b, 301c, and 301d is disposed. Therefore, the color ink discharge heads 301a, 301b, 301c, and 301d are collectively referred to as color ink discharge heads 301, and each of the color ink discharge heads 301a, 301b, 301c, and 301d is simply referred to as a color ink discharge head 301 in the following description unless otherwise distinguished. In addition, since the irradiation units 400a and 400b have the same configuration except for the position where each of the irradiation units 400a and 400b is disposed, the irradiation units 400a and 400b are collectively referred to as irradiation units 400, and each of the irradiation units 400a and 400b is simply referred to as an irradiation unit 400 in the following description unless otherwise distinguished. The metallic ink discharge head 300 also has the same configuration as the color ink discharge heads 301 except for the type of ink to be discharged and the position thereof, but do not necessarily have the same configuration.

The carriage 200 holds the metallic ink discharge head 300, the color ink discharge heads 301, and the irradiation units 400 each of which faces the sheet P placed below the carriage 200 in −Z direction. The metallic ink discharge head 300 includes a piezoelectric element as a pressure generator. The piezoelectric element is contracted in response to drive signals, thereby changing the pressure of the metallic ink in the metallic ink discharge head 300. Accordingly, the metallic ink is discharged in −Z direction through each nozzle included in a nozzle row 300n of the metallic ink discharge head 300.

The metallic ink according to the present embodiment is an ultraviolet curable ink and includes at least a monomer or an oligomer, a photopolymerization initiator, and metallic particles. For example, an ink containing a methacrylate monomer can be used as the ultraviolet curable ink. Methacrylate monomer has characteristics of relatively weak skin sensitization and large cure shrinkage. The ultraviolet curable ink may further include an additive. Examples of the additive includes a sensitizer, a dispersant, a leveling agent, or a polymerization inhibitor, and the additive can be appropriately selected.

In the present embodiment, the metallic particles are made of aluminum and has a scaly or flat shape having an outer diameter of about 5 μm and a thickness of about 0.1 μm to 0.2 μm. The metallic particles are not limited thereto, and metal other than aluminum can be used as the material of the metallic particles. The shape of the metallic particles is not limited to be scaly or flat.

The color ink discharge head 301 includes a piezoelectric element as a pressure generator. The piezoelectric element is contracted in response to drive signals, thereby changing the pressure of the color ink in the color ink discharge head 301. Accordingly, the color ink is discharged in −Z direction through each nozzle included in a nozzle row 301n of the color ink discharge head 301.

The color ink according to the present embodiment is an ultraviolet curable ink and includes at least a monomer or an oligomer, a photopolymerization initiator, and colored particles. The colored particles are particles of a dye, a pigment, or the like. The colors of the colored particles are, for example, cyan, magenta, yellow, and black, but are not limited thereto, and can be appropriately selected according to the use of the image forming apparatus 10.

The material of the ultraviolet curable ink is not particularly limited to the above, and various materials can be appropriately used according to the use of the image forming apparatus 10. The same applies to the viscosity and surface tension of the ink. At least one of the metallic ink or the color ink preferably includes a solvent to increase volatility and improve curing efficiency or drying efficiency. At least one of the metallic ink or the color ink preferably includes water from the viewpoint of environmental resistance.

The irradiation unit 400 irradiates the metallic ink and the color ink on the sheet P with light. The irradiation unit 400a is an example of a forward irradiation unit, and the irradiation unit 400b is an example of a backward irradiation unit. In the present embodiment, the irradiation unit 400 emits the ultraviolet rays to cure the metallic ink and the color ink on the sheet P. The cured metallic ink and color ink are adhered to and fixed on the sheet P. As the irradiation unit 400, for example, an ultraviolet (UV) lamp can be used.

The length of the irradiation unit 400 in the sub-scanning direction is preferably longer than each length of the metallic ink discharge head 300 and the color ink discharge heads 301 in the sub-scanning direction. Thus, the irradiation unit 400 can irradiate the entire ink discharged by the metallic ink discharge head 300 or the color ink discharge head 301 onto the sheet P in the sub-scanning direction with ultraviolet rays in one main scanning movement.

As illustrated in FIG. 2, in the carriage 200, the metallic ink discharge head 300, the color ink discharge heads 301, and the irradiation units 400 are disposed side by side in the main scanning direction. In the carriage 200, the color ink discharge head 301 and the irradiation unit 400 are disposed on each side of the metallic ink discharge head 300, and the color ink discharge head 301 is closer to the metallic ink discharge head 300 than the irradiation unit 400 is.

Specifically, on the side of the metallic ink discharge head 300 in −X direction, the color ink discharge head 301a is disposed upstream from the metallic ink discharge head 300, the color ink discharge head 301b is disposed upstream from the color ink discharge head 301a, and the irradiation unit 400a is disposed upstream from the color ink discharge head 301b in the direction of the forward main scanning movement. Further, on the side of the metallic ink discharge head 300 in +X direction, the color ink discharge head 301c is disposed upstream from the metallic ink discharge head 300, the color ink discharge head 301d is disposed upstream from the color ink discharge head 301c, and the irradiation unit 400b is disposed upstream from the color ink discharge head 301d in the direction of the backward main scanning movement.

Next, a configuration of hardware of the image forming apparatus 10 is described with reference to FIG. 3. FIG. 3 is a block diagram illustrating the configuration of hardware of the image forming apparatus 10. As illustrated in FIG. 3, the image forming apparatus 10 includes a controller unit 3, sensors 4, a conveyance unit 100, the carriage 200, the metallic ink discharge head 300, the color ink discharge head 301, the irradiation unit 400, and a maintenance unit 500.

The controller unit 3 includes a unit control circuit 31, a memory 32, a central processing unit (CPU) 33, and an interface (I/F) 34. The I/F 34 connects the image forming apparatus 10 to a personal computer (PC) 26 as an external device. The image forming apparatus 10 and the PC 26 may be connected in any form, for example, via a network or directly connected by a communication cable.

The CPU 33 uses the memory 32 as a working area to control an operation of each unit of the image forming apparatus 10 such as the conveyance unit 100, the carriage 200, the metallic ink discharge head 300, the color ink discharge head 301, the irradiation unit 400, and the maintenance unit 500 via the unit control circuit 31. Specifically, the CPU 33 controls the operation of each unit based on image data received from the PC 26 and data detected by the sensors 4 to form an image on the sheet P.

The sensors 4 includes various sensors provided in the image forming apparatus 10, for example, an encoder sensor that detects the position of the carriage 200 in the main scanning direction. A printer driver is installed in the PC 26. The printer driver generates image data to be transmitted to the image forming apparatus 10. The image data includes command data for operating the carriage 200 of the image forming apparatus 10 and pixel data related to an image to be formed.

The conveyance unit 100 includes a conveyance mechanism to convey the sheet P. The conveyance unit 100 is an example of a moving unit that performs the main scanning movement in which the carriage 200 is moved relative to the sheet P in the main scanning direction and the sub-scanning movement in which the carriage 200 is moved relative to the sheet P in the sub-scanning direction. The conveyance unit 100 includes the guide rod 19, the guide rail 29, and the like.

The maintenance unit 500 maintains and recovers the discharge function of the metallic ink discharge head 300 and the color ink discharge head 301. The maintenance unit 500 further includes a cap that covers the nozzle surface of the metallic ink discharge head 300 and the color ink discharge head 301 to protect the nozzles from drying when the image forming apparatus 10 does not form an image.

The cap is a moisture-retentive cap having a function of simply covering the nozzle surface to protect the nozzle surface from drying. Alternatively, the cap may be a suction cap coupled to a suction pump. In addition to the function of the moisture-retentive cap, the suction cap sucks thickened ink from the metallic ink discharge head 300 and the color ink discharge head 301 by the suction pump.

Next, a functional configuration of the controller unit 3 included in the image forming apparatus 10 is described. FIG. 4 is a block diagram illustrating an example of the functional configuration of the controller unit 3. As illustrated in FIG. 4, the controller unit 3 includes an image processor 12 and a controller 30.

The image processor 12 includes a data reception unit 121, a data generation unit 122, and a data output unit 123. The data reception unit 121 receives image data from the PC 26. The image data includes information indicating a pattern and color of an image to be formed. The data generation unit 122 performs predetermined data processing such as color (cyan, magenta, yellow, and black) conversion processing, gradation reduction processing, and image conversion processing on the image data received by the data reception unit 121, and generates recording data for forming an image on the sheet P based on the image data. The data output unit 123 outputs the generated recording data to the controller 30.

The controller 30 includes a discharge control unit 14, a print mode reception unit 21, an irradiation drive unit 22, a first drive unit 23, a second drive unit 24, and an image formation control unit 25.

The discharge control unit 14 causes the metallic ink discharge head 300 and the color ink discharge head 301 to discharge ink based on the recording data. The print mode reception unit 21 receives data of a print mode. The print mode indicates color printing or monochrome printing, printing on one side or both sides of the sheet P, or the like. The irradiation drive unit 22 drives the irradiation unit 400 to emit ultraviolet rays.

The first drive unit 23 causes the conveyance unit 100 to move the carriage 200 in the sub-scanning direction so as to move the carriage 200 and the sheet P relative to each other in the sub-scanning direction. The second drive unit 24 causes the conveyance unit 100 to move the carriage 200 in the main scanning direction so as to move the carriage 200 and the sheet P relative to each other in the main scanning direction.

The image formation control unit 25 receives recording data from the image processor 12, and controls the discharge control unit 14, the irradiation drive unit 22, the first drive unit 23, and the second drive unit 24 to cause the metallic ink discharge head 300 and the color ink discharge heads 301 to discharge inks corresponding to each pixel of the recording data.

Next, an operation of the image forming apparatus 10 is described with reference to FIG. 5. FIG. 5 is a flowchart illustrating an operation of the image forming apparatus 10. FIG. 5 illustrates the operation triggered by a timing to start image formation control after the image forming apparatus 10 receives image data from the PC 26 and recording data is generated.

First, in step S51, the image formation control unit 25 moves the carriage 200 in the sub-scanning direction and stops the carriage 200 at an initial position for forming an image. Subsequently, in step S52, the image formation control unit 25 drives a lift to move the carriage 200 to a height suitable for discharging ink by the metallic ink discharge head 300 and the color ink discharge head 301.

The height means a position of the carriage 200 along the Z-axis direction. At this height, for example, a gap between the sheet P and, the metallic ink discharge head 300 and the color ink discharge head 301 is 1 mm. The image formation control unit 25 preferably drives the lift based on detection signals from a height sensor that detects the height of the metallic ink discharge head 300 and the color ink discharge head 301. Subsequently, in step S53, the image formation control unit 25 initializes the number of times n to 1.

In step S54, the image formation control unit 25 moves the carriage 200 forward in the first main scanning movement, in other words, performs the forward main scanning movement. In the first main scanning movement, in step S55, the metallic ink discharge head 300 discharges the metallic ink in a first region of the sheet P. In this case, the metallic ink discharge head 300 corresponds to a forward metallic ink discharge head. In the first main scanning movement, in step S56, the color ink discharge heads 301a and 301b discharge the color ink in the first region of the sheet P. In this case, the color ink discharge heads 301a and 301b correspond to a forward color ink discharge head.

Further, in the first main scanning movement, in step S57, the irradiation unit 400a irradiates the metallic ink and the color ink discharged in the first region of the sheet P with ultraviolet rays. In this case, the irradiation unit 400a corresponds to a forward irradiation unit. As a result, the metallic ink and the color ink discharged in the first region of the sheet P is cured and fixed on the sheet P.

After the image formation control starts, the irradiation unit 400a continuously turns on the UV lamp and continues emitting ultraviolet rays. When the irradiation unit 400a faces the metallic ink and the color ink discharged in the first region of the sheet P, the irradiation unit 400a irradiates the metallic ink and the color ink with ultraviolet rays. At that time, the first region and the irradiation unit 400a overlap each other in a direction in which the sheet P is viewed in plan view.

The irradiation unit 400 may be controlled such that the UV lamp is turned on only when the irradiation unit 400 faces the metallic ink or the color ink discharged in the first region of the sheet P, and the UV lamp is turned off in other times. The same applies to the subsequent irradiation of ultraviolet rays described later by the irradiation unit 400.

In the carriage 200, on the side of the metallic ink discharge head 300 in −X direction, the color ink discharge head 301a is disposed upstream from the metallic ink discharge head 300, the color ink discharge head 301b is disposed upstream from the color ink discharge head 301a, and the irradiation unit 400a is disposed upstream from the color ink discharge head 301b in the direction of the forward main scanning movement.

Therefore, in the first main scanning movement which is the forward main scanning movement, the metallic ink discharge head 300 discharges the metallic ink and the color ink discharge heads 301a and 301b discharge the color ink to the first region in this order. Then, when the irradiation unit 400a faces the metallic ink and the color ink discharged in the first region, the irradiation unit 400a emits ultraviolet rays.

The metallic ink discharge head 300 discharges the metallic ink before the color ink discharge head 301 discharges the color ink. As a result, in the first main scanning movement, the time from the discharge of the metallic ink to the start of curing the metallic ink is secured longer than the time from the discharge of the color ink to the start of curing the color ink in the first region of the sheet P. After the first main scanning movement ends, the image formation control unit 25 stops the carriage 200.

In step S58, the image formation control unit 25 moves the carriage 200 backward in the main scanning direction as a second main scanning movement (i.e., the backward main scanning movement). In the second main scanning movement, in step S59, the metallic ink discharge head 300 discharges the metallic ink in the first region of the sheet P. The metallic ink discharge head 300 corresponds to a backward metallic ink discharge head. That is, in the present embodiment, the metallic ink discharge head 300 serves as both the forward metallic ink discharge head and the backward metallic ink discharge head.

In the second main scanning movement, in step S60, the color ink discharge heads 301c and 301d discharge the color ink in the first region of the sheet P. In this case, the color ink discharge heads 300c and 300d correspond to a backward color ink discharge head. Further, in the second main scanning movement, in step S61, the irradiation unit 400b irradiates the metallic ink and the color ink discharged in the first region of the sheet P with ultraviolet rays. In this case, the irradiation unit 400b corresponds to a backward irradiation unit. As a result, the metallic ink and the color ink discharged in the first region of the sheet P are cured and fixed on the sheet P, thereby forming an image in the region.

In the carriage 200, on the side of the metallic ink discharge head 300 in +X direction, the color ink discharge head 301c is disposed upstream from the metallic ink discharge head 300, the color ink discharge head 301d is disposed upstream from the color ink discharge head 301c, and the irradiation unit 400b is disposed upstream from the color ink discharge head 301b in the direction of the backward main scanning movement.

Therefore, in the second main scanning movement which is the backward main scanning movement, the metallic ink discharge head 300 discharges the metallic ink, and the color ink discharge heads 301c and 301d discharge the color ink in the first region in this order. Then, the irradiation unit 400b irradiates the metallic ink and the color ink discharged in the first region with ultraviolet rays.

As described above, the metallic ink discharge head 300 discharges the metallic ink before the color ink discharge head 301 discharges the color ink. Therefore, in the second main scanning movement, the time from the discharge of the metallic ink to the start of curing the metallic ink is secured to be longer than the time from the discharge of the color ink to the start of curing the color ink. After the second main scanning movement ends, the image formation control unit 25 stops the carriage 200.

Subsequently, in step S62, the image formation control unit 25 determines whether to end the image formation. For example, the image formation control unit 25 checks whether or not the number of main scanning movements has reached a predetermined number to determine to end the image formation.

When the image formation control unit 25 determine to end the image formation (Yes in step S62), the image formation control unit 25 ends the image formation. When the image formation control unit 25 determine not to end the image formation (No in step S62), in step S63, the image formation control unit 25 moves the carriage 200 in the sub-scanning direction by a predetermined distance in the sub-scanning direction (i.e., a sub-scanning distance). The sub-scanning distance is substantially equal to the lengths of the nozzle rows 300n and 301n along the sub-scanning direction.

Subsequently, in step S64, the image formation control unit 25 adds 1 to the number of times n. After that, the image formation control unit 25 performs the operation in step S54 and beyond again. Although the operation from steps S54 to S61 when the number of times n is equal to 1 is described above, when the number of times n is equal to 2 or more, the number of main scanning movements and the region number (i.e., nth region) increase according to the number of times n. In the present embodiment, for example, since an image is formed in the same region by the forward main scanning movement and the backward main scanning movement, the number of the main scanning movements is (n×2−1) times in the forward main scanning movement and (n×2) times in the backward main scanning movement according to the number of times n.

Thereafter, the image forming apparatus 10 repeats the forward main scanning movement, the backward main scanning movement, and the sub-scanning movement until the image formation on the sheet P ends to form an image on a predetermined region of the sheet P.

FIGS. 6A to 6D are plan views of the sheet P on which images are formed in first to fourth main scanning movements, respectively. First, the conveyance unit 100 performs the forward main scanning movement as a first main scanning movement in which the carriage 200 is moved forward in the main scanning direction. At that time, the metallic ink discharge head 300 discharges the metallic ink, and the color ink discharge heads 301a and 301b discharge the color ink in a first region 61 in this order. Thereafter, the irradiation unit 400a irradiates the first region 61 with ultraviolet rays. As a result, as illustrated in FIG. 6A, an image 61a by the first main scanning movement is formed in the first region 61.

Next, the conveyance unit 100 performs the backward main scanning movement as a second main scanning movement in which the carriage 200 is moved backward in the main scanning direction. At that time, the metallic ink discharge head 300 discharges the metallic ink, and the color ink discharge heads 301c and 301d discharge the color ink in the first region 61 in this order. Thereafter, the irradiation unit 400b irradiates the first region 61 with ultraviolet rays.

As a result, as illustrated in FIG. 6B, an image 61b by the second main scanning movement is formed in the first region 61. The color ink discharge head 301 may discharge the color ink onto the metallic ink discharged in the first region 61, or may discharge the color ink in an area where the metallic ink is not discharged in the first region 61 to complement the metallic ink.

After performing the sub-scanning movement, the conveyance unit 100 performs the forward main scanning movement as a third main scanning movement. At that time, the metallic ink discharge head 300 discharges the metallic ink, and the color ink discharge heads 301a and 301b discharge the color ink in a second region 62 in this order. The second region 62 is shifted by the sub-scanning distance downstream from the first region 61 in +Y direction along the sub-scanning direction. Thereafter, the irradiation unit 400a irradiates the second region 62 with ultraviolet rays. As a result, as illustrated in FIG. 6C, an image 61c by the third main scanning movement is formed in the second region 62.

Next, the conveyance unit 100 performs the backward main scanning movement as a fourth main scanning movement. At that time, the metallic ink discharge head 300 discharges the metallic ink, and the color ink discharge heads 301c and 301d discharge the color ink in the second region 62 in this order. Thereafter, the irradiation unit 400b irradiates the second region 62 with ultraviolet rays. As a result, as illustrated in FIG. 6D, an image 61d by the fourth main scanning movement is formed in the second region 62. As described above, the image formation is performed in each region for each main scanning movement to form an image in a predetermined region of the sheet P.

Next, operational effects of the image forming apparatus 10 is described. When an image is formed using an ink such as a metallic ink containing metal particles, the glossiness of the metallic ink is preferably improved. In particular, the ultraviolet curable ink is likely to be thick when forming an image, and the glossiness of the image may vary depending on the thickness of the ink. Therefore, there is room for improvement in the glossiness.

As a result of diligent studies on the glossiness of such a metallic ink, the inventor has found that the glossiness of an image is improved by prolonging the time from the discharge of the metallic ink to the irradiation of light by the irradiation unit 400. The reason for this is assumed as follows.

If the metallic ink is irradiated with light immediately after landing on a recording medium, the metallic ink is cured in a state immediately after landing on the recording medium. On the other hand, if the time from when the metallic ink lands on the recording medium to when the metallic ink is irradiated with light is prolonged, the metallic ink wets and spreads on the recording medium before being cured. As a result, the metallic ink is likely to be thin when forming an image, and a large number of metal foil pieces included in the metallic ink are likely to be oriented parallel to the recording medium. The image including a large number of metal foil pieces oriented parallel to the recording medium is likely to reflect light in the same direction without scattering the light, thereby improving the glossiness of the image.

For this reason, the image forming apparatus 10 according to the present embodiment includes the ink discharge head (liquid discharge head) that discharges ink (liquid) onto a sheet P (recording medium), the irradiation unit 400 that irradiates the ink on the sheet P with ultraviolet rays (light), and the carriage 200 on which the ink discharge head and the irradiation unit 400 are mounted. The image forming apparatus 10 further includes the conveyance unit 100 (moving unit) that performs the main scanning movement in which the carriage 200 is moved relative to the sheet P in the main scanning direction and the sub-scanning movement in which the carriage 200 is moved relative to the sheet P in the sub-scanning direction perpendicular to the main scanning direction.

The ink includes the metallic ink and the color ink. Further, the ink discharge head discharges the metallic ink in a region of the sheet P in the main scanning movement, and discharges the color ink in the region in which the metallic ink has been discharged, in the same main scanning movement in which the metallic ink is discharged. Thereafter, the irradiation unit 400 irradiates the region in which the metallic ink and the color ink have been discharged, with the light in the same main scanning movement.

As a result, the ink discharge head discharges the metallic ink before discharging the color ink. Therefore, in the main scanning movement, the time from the discharge of the metallic ink to the start of curing the metallic ink can be longer than the time from the discharge of the color ink to the start of curing the color ink. As a result, the glossiness of an image including the metallic ink is improved, and a colored and highly glossy image such as a metallic color image can be formed.

In the present embodiment, a long time from the discharge of the metallic ink to the start of curing the metallic ink can be secured without moving the carriage 200 at a slow speed or stopping the carriage 200. Therefore, the high productivity of image formation can be secured while improving the glossiness of the image.

In addition, in the present embodiment, the main scanning movement includes the forward main scanning movement and the backward main scanning movement. The liquid discharge head includes the metallic ink discharge head 300 that discharges the metallic ink and the color ink discharge heads 301a, 301b, 301c, and 301d that discharge the color ink. The irradiation unit 400 includes the irradiation units 400a and 400b.

The color ink discharge head 301 and the irradiation unit 400 are disposed on each side of the metallic ink discharge head 300 on the carriage 200. The color ink discharge heads 301a and 301b is closer to the metallic ink discharge head 300 than the irradiation unit 400a is, and the color ink discharge heads 301c and 301d is closer to the metallic ink discharge head 300 than the irradiation unit 400b is.

As a result, the metallic ink and the color ink are cured in the image formation in each of the forward main scanning movement and the backward main scanning movement, and the metallic ink and the color ink are superimposed onto each other. Thus, the amount of ink on the sheet P can be secured, thereby securing high productivity of image formation while increasing the glossiness of the image.

In the present embodiment, the metallic ink and the color ink are discharged in the same region in the forward main scanning movement and the backward main scanning movement. Alternatively, in another embodiment, the image formation may be performed in different regions shifted in the sub-scanning direction in the forward main scanning movement and the backward main scanning movement. Also in this case, the metallic ink and the color ink can be cured with high productivity while increasing the glossiness of an image.

Further, in the present embodiment, a configuration in which ultraviolet curable ink is used has been described as an example, but is not limited thereto. For example, an ink which is cured by light energy such as infrared rays or thermal energy may be used, but the ultraviolet curable ink is preferable from the viewpoint of curing efficiency.

In the present embodiment, the operation of the image forming apparatus that moves the carriage in both the main scanning direction and the sub-scanning direction has been described as an example, but not limited thereto. For example, the carriage may be moved in the main scanning direction, and the sheet P may be moved in the sub-scanning direction.

FIG. 7 is a perspective view illustrating another example of the configuration of such an image forming apparatus. In FIG. 7, an image forming apparatus 10a is viewed from obliquely above, and the interior thereof can be partially seen through the housing thereof. As illustrated in FIG. 7, the image forming apparatus 10a includes an apparatus body 101, a feeding device 102, and a winding device 103. The feeding device 102 is a medium supply device that is disposed below the apparatus body 101 and supplies a sheet P wound in a roll shape. The sheet P wound in a roll shape is an example of a recording medium.

A roll 112 that is the sheet P wound around a hollow shaft 115 is held in the feeding device 102. The winding device 103 includes a hollow shaft 114 for winding the sheet P. The sheet P is wound around the hollow shaft 114 as a roll 112. Note that the feeding device 102 and the winding device 103 may be integrally formed with the apparatus body 101 instead of being separately formed.

The feeding device 102 supplies the sheet P into the apparatus body 101. In the apparatus body 101, an image forming unit 104 forms an image on the sheet P supplied in a conveyance direction indicated by arrow B. The image forming unit 104 includes a guide rod 1 and a guide stay 2 as guides that are bridged between both side plates. The carriage 200 is supported by the guide rod 1 and the guide stay 2 so as to be movable in the main scanning direction indicated by arrow A. The winding device 103 winds the sheet P on which an image has been formed.

A main scanning motor 8 as a driving source to reciprocate the carriage 200 is disposed on one side in the main scanning direction. The main scanning motor 8 rotates a drive pulley 9. A timing belt 11 is wound around the drive pulley 9 and a driven pulley 20 disposed on the other side in the main scanning direction. A belt holding portion of the carriage 200 is secured to the timing belt 11. As the main scanning motor 8 is driven, the carriage 200 is reciprocated in the main scanning direction.

With the carriage 200 illustrated in FIG. 2, the image forming apparatus 10a having such a configuration can obtain the same effect as that of the above-described image forming apparatus 10.

In the above-described embodiments, the configuration in which the carriage 200 moves in both the main scanning direction and the sub-scanning direction and the configuration in which the carriage moves in the main scanning direction and the sheet P moves in the sub-scanning direction are described as examples, but the configuration is not limited thereto. As long as the sheet P and the carriage can move relative to each other, a configuration in which the sheet P moves in both the main scanning direction and the sub-scanning direction or a configuration in which the sheet P moves in the main scanning direction and the carriage moves in the sub-scanning direction may be employed.

Next, an image forming apparatus 10b according to a second embodiment of the present disclosure is described. The same components described in the first embodiment are denoted by the same reference numerals, and redundant description thereof is omitted as appropriate.

The image forming apparatus 10b can perform the bidirectional printing in which an image is formed in each of the forward main scanning movement and the backward main scanning movement. The overall configuration of the image forming apparatus 10 or the image forming apparatus 10a described above can be applied to the image forming apparatus 10b. In the image forming apparatus 10b, the arrangement of the ink discharge heads on the carriage is different from that of the image forming apparatus 10 or the image forming apparatus 10a.

FIG. 8 is a plan view of a carriage 200b of the image forming apparatus 10b. As illustrated in FIG. 8, the carriage 200b includes metallic ink discharge heads 300a and 300b that discharge the metallic ink, and the color ink discharge heads 301a, 301b, 301c, and 301d that discharge the color ink.

In the carriage 200b, the color ink discharge head 301a as a forward color ink discharge head is disposed upstream from the metallic ink discharge head 300a as a forward metallic ink discharge head, the color ink discharge head 301b as a forward color ink discharge head is disposed upstream from the color ink discharge head 301a, and the irradiation unit 400a as a forward irradiation unit is disposed upstream from the color ink discharge head 301b in the direction of the forward main scanning movement. Further, the color ink discharge head 301c as a backward color ink discharge head is disposed upstream from the metallic ink discharge head 300b as a backward metallic ink discharge head, the color ink discharge head 301d as a backward color ink discharge head is disposed upstream from the color ink discharge head 301c, and the irradiation unit 400b as a backward irradiation unit is disposed upstream from the color ink discharge head 301d in the direction of the backward main scanning movement.

With this arrangement, in the image forming apparatus 10b, the ink discharge head discharges the metallic ink before discharging the color ink. Therefore, in the main scanning movement, the time from the discharge of the metallic ink to the start of curing the metallic ink can be longer than the time from the discharge of the color ink to the start of curing the color ink. As a result, the glossiness of an image including the metallic ink can be improved.

Further, in the present embodiment, the distance between the metallic ink discharge head and the irradiation unit along the main scanning direction is longer than that of the arrangement of the metallic ink discharge head, the color ink discharge head, and the irradiation unit on the carriage 200 described in the first embodiment. For this reason, the time from the discharge of the metallic ink to the start of curing the metallic ink can be secured long, thereby improving the glossiness of an image including the metallic ink.

In another example of such a configuration, the color ink discharge heads 301c and 301d as a backward color ink discharge head may be omitted, and the color ink discharge heads 301a and 301b as a forward color ink discharge head may also serve as a backward color ink discharge head.

The above-described embodiments are just examples and do not limit the present disclosure. Modifications and alterations of the embodiments can be made without departing from the spirit and scope of the embodiments of the present disclosure described in the claims unless limited in the above description.

Embodiments also include an image forming method. An image forming method includes discharging a liquid onto a recording medium, irradiating the liquid on the recording medium with light, and performing a main scanning movement and a sub-scanning movement. In the main scanning movement, positions where the liquid is discharged and the light is emitted are moved relative to the recording medium in a main scanning direction. In the sub-scanning movement, the positions where the liquid is discharged and the light is emitted are moved relative to the recording medium in a sub-scanning direction perpendicular to the main scanning direction. The liquid includes a metallic ink and a color ink. The image forming method further includes discharging the metallic ink in a region of the recording medium in the main scanning movement, discharging the color ink in the region in which the metallic ink has been discharged, in the same main scanning movement in which the metallic ink is discharged, and irradiating the region in which the metallic ink and the color ink have been discharged, with the light in the same main scanning movement. According to such an image forming method, the same effects as those of the above-described image forming apparatus can be obtained. Such an image forming method may be implemented by a circuit such as a CPU or a large-scale integration (LSI), an integrated circuit (IC) card, a single module, or the like.

Embodiments also include a non-transitory storage medium storing a program which, when executed by one or more processors, causes the one or more processors to perform the image forming method. For example, a non-transitory storage medium stores a program which, when executed by one or more processors, causes the one or more processors to perform an image forming method. The method includes discharging a liquid onto a recording medium, irradiating the liquid on the recording medium with light, and performing a main scanning movement and a sub-scanning movement. In the main scanning movement, positions where the liquid is discharged and the light is emitted are moved relative to the recording medium in a main scanning direction. In the sub-scanning movement, the positions where the liquid is discharged and the light is emitted are moved relative to the recording medium in a sub-scanning direction perpendicular to the main scanning direction. The liquid includes a metallic ink and a color ink. The image forming method further includes discharging the metallic ink in a region of the recording medium in the main scanning movement, discharging the color ink in the region in which the metallic ink has been discharged, in the same main scanning movement in which the metallic ink is discharged, and irradiating the region in which the metallic ink and the color ink have been discharged, with the light in the same main scanning movement. According to such a program for performing the image forming method, effects similar to those of the above-described image forming apparatus can be obtained.

In addition, the numbers such as ordinal numbers and quantities used in the above-described embodiments are all examples for specifically describing the technology of the present disclosure, and embodiments of the present disclosure are not limited to the exemplified numbers. In addition, the above-describe connections among the components are examples for specifically describing the technology of the present disclosure, and connections for implementing functions of the present disclosure are not limited to the above-described examples.

Further, division of functional blocks illustrated in the block diagram is an example, and a plurality of blocks may be implemented as one block, one block may be divided into a plurality of blocks, and/or some functions may be transferred to another block. Further, functions of a plurality of blocks having similar functions may be processed in parallel or in time division by a single piece of hardware or software.

The above-described embodiments are illustrative and do not limit the present disclosure. Thus, numerous additional modifications and variations are possible in light of the above teachings. For example, elements and/or features of different illustrative embodiments may be combined with each other and/or substituted for each other within the scope of the present disclosure.

Any one of the above-described operations may be performed in various other ways, for example, in an order different from the one described above.

Each of functions of the above-described embodiments can be implemented by one or more processing circuits. Here, the term “processing circuit or circuitry” in the present specification includes a programmed processor to execute each function by software, such as a processor implemented by an electronic circuit, and devices, such as an application specific integrated circuit (ASIC), a digital signal processors (DSP), a field programmable gate array (FPGA), and conventional circuit components arranged to perform the recited functions.

Number	Date	Country	Kind
2021-057704	Mar 2021	JP	national
2021-179286	Nov 2021	JP	national

IMAGE FORMING APPARATUS, IMAGE FORMING METHOD, AND STORAGE MEDIUM

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