The present invention relates to a deposition method for ink-jet printing.
Ink-jet printing methods are well known and widely used, not only for printing text or images on surfaces of all types, but also for many other applications. They consist of displacing a movable head relative to a receiving medium, with the head having at least one nozzle that is controlled so that it ejects predefined amounts of a substance at controlled moments during the displacement of the head. Each nozzle is aimed at the medium, so that the ejected amounts of substance reach the medium at points of impact that are initially determined. The medium is also adapted so that the amount of substance received at a point remains at the location of that point, without any subsequent diffusion or migration of the substance on the medium.
The substance deposited by such a method may vary in appearance and type, depending on the application concerned. Examples include ink, glue, index liquid, powder, etc.
The head may be equipped with several nozzles to increase pattern print speed. These nozzles may be activated independently of each other and at the same time. Most often, they are placed on the head in one or more oblique rows or columns.
Also, several different technologies exist for the nozzles, depending on the substance to be deposited. As examples, there are nozzles in which the ejection of an amount of substance is caused by an piezoelectric element, and nozzles in which a bubble is rapidly heated to cause the ejection of the amount of substance.
Ink-jet printing deposition is fast, efficient, and compatible with many different substances. It does have the following disadvantage, however.
During operation, the nozzles carried by the head are at a distance from the surface of the receiving medium. The amounts of substance ejected by the nozzles travel across the space between the nozzle and the medium, called the ejection distance. This ejection distance is constant, at a value which is set or recommended by the head manufacturer.
But, for various reasons related to nozzle manufacturing, the ejection direction for each nozzle is poorly controlled. Each nozzle ejects its amounts of substance in a direction which may be angled relative to the general orientation of the head. This angle in the ejection direction is constant for the same nozzle: all amounts of substance successively ejected by this nozzle have the same ejection direction. Nozzles on the same head may, however, have ejection directions that differ between nozzles. The angle of the ejection direction of a nozzle may be due to the axis of this nozzle being angled relative to the head, or to a defect in the shape of the nozzle outlet, rough spots in the outlet, variations in the surface tension at this outlet, etc. The entire description that follows is limited to considering these types of angle in the ejection direction, which are permanent. It also applies to compensating for unwanted offsets in nozzle outlets relative to the theoretical positions of these outlets on the head. It does not concern temporary variations in the nozzle ejection directions which may be caused by partial obstruction of the outlets. It is known that such temporary variations can be eliminated by nozzle cleaning operations.
Because of the ejection distance between the outlet of each nozzle and the surface of the medium, the angle of the ejection direction results in a deviation between the point of impact on the medium of the ejected amount of substance and the perpendicular projection from the nozzle outlet onto that medium. Various symptoms of this deviation may be apparent, depending on the print pattern and the medium used. In particular, convergent deviations for amounts of substance deposited next to each other may produce dark visible lines perpendicular to the direction of convergence. Conversely, divergent deviations may produce light lines.
Another symptom of deviations in the nozzle ejection directions appears when the medium receiving the substance has a structure to its surface. Unwanted variations appear in the density of the deposition which are due to superimposing each ejection deviation on the medium structure. These variations in the deposition density form moiré patterns, with a period which results from combining the ejection deviations with the medium structure. This moiré period may be about a millimeter, even if the ejection deviations on the medium and the characteristic dimension of the medium are each less than a millimeter or a tenth of a millimeter. Such moiré patterns can therefore be visible and constitute unacceptable aesthetic defects.
To avoid such moiré defects, one proposal has been to determine whether at least one of the nozzles of a head to be used has a deviation in its ejection direction. Such a nozzle with an oblique ejection direction is then neutralized during a later deposition sequence, so that only the nozzles ejecting their amounts of the substance without deviation are used. However, the proportion of nozzles on a deposition head that are neutralized for this reason may be high, significantly reducing the resulting deposition rate obtained with the remaining nozzles.
Under these conditions, an object of the present invention consists of improving the quality of depositions made using an ink-jet printing deposition method.
More specifically, an object of the invention is to eliminate deposition defects resulting from the existence of nozzles in the deposition head that have permanently oblique or misaligned ejection directions.
In particular, an object of the invention is to perform depositions of a higher level of quality onto media which may have a periodic or non-periodic surface structure.
In order to achieve these and other objects, the invention proposes a method for depositing a substance onto a receiving medium for this substance, by means of ink-jet printing using a head which is movable relative to the medium in two directions, transverse and longitudinal, that are perpendicular to each other. The head comprises at least one set of multiple ejection nozzles which are longitudinally offset relative to each other and which are each adapted to eject amounts of the substance in the direction of the medium with a fixed distance between the nozzle and the medium. The method comprises the following steps:
Thus, a method of the invention therefore comprises an initial step for determining the ejection deviation of each nozzle of the head. During a later deposition sequence, the head is successively placed facing the medium at variable offsets, to compensate for the ejection deviations of the nozzles. The only nozzles activated at each offset are those for which compensation is obtained. Thus any ejection deviation of a nozzle is canceled out by offsetting this nozzle relative to the target point at the moment of ejection. The point of impact of the amount of substance ejected onto the medium therefore coincides with the target point.
In this manner, no dark or light line, or more generally no unwanted coverage or empty interval between the depositions for neighboring target points occurs. The quality of the deposition obtained is therefore improved.
Also, no moiré pattern is produced when the medium receiving the substance has a surface structure.
In particular, if the medium has a surface structure that is irregular or random, no moiré pattern is formed even when the target points form a regular grid on the medium surface, if this grid is sufficiently small relative to the pattern of the medium's surface structure.
In addition, all the nozzles of the head can be used in a method according to the invention.
In different embodiments of the invention, the following improvements may be used individually or in any combination:
In preferred implementations of the invention, a deposition line running parallel to the transverse direction may be made starting from each longitudinal offset of the head. The head is then moved parallel to the transverse direction in each iteration of step /5/, and the nozzles selected for the longitudinal offset of the head which is achieved during this iteration are activated during the transverse movement of the head according to the predetermined amounts of substance to be deposited on the medium at the transverse offset locations, and the nozzles that are not selected for this longitudinal offset of the head are not activated during the transverse movement.
In this case of deposition in transverse rows, the invention may be supplemented to compensate for, in addition to longitudinal ejection deviations, additional ejection deviations which are parallel to the transverse direction. Such compensations for transverse ejection deviations by the nozzles are achieved by adjusting an advance or delay in triggering the ejection of the amount of substance by each nozzle concerned, during the transverse movement of the head as it travels a row. To do this, a method of the invention may be supplemented as follows:
To deposit amounts of substance in several transverse rows that are longitudinally offset, a length of the medium in this longitudinal direction is greater than a longitudinal step distance which corresponds to a distance between the extreme nozzles of the head that are longitudinally opposite. Step /6/ is then repeated by adding this longitudinal increment to the longitudinal offsets of the head which are applied during the iterations of step /5/.
Other features and advantages of the invention will be apparent from the following description of some non-limiting implementation examples, with reference to the attached drawings in which:
a is a plan view of a substance receiving medium which can be used to implement the invention;
b is a cross-sectional view of the medium of
a and 2b are respectively front and profile views of a deposition head which can be used to implement the invention;
c shows ejection deviations in the plane of the medium;
For sake of clarity, the dimensions of the elements represented in these figures do not correspond to the actual dimensions or to the ratios between actual dimensions. In addition, the same references used in different figures denote identical elements or those with identical functions.
In
The medium 100 may be of any type that is able to receive local amounts of substance which remain affixed without diffusion or migration parallel to the receiving surface of this medium. An amount of substance deposited at a location on the medium 100 definitively remains at that location.
For example, as is represented in the enlarged portion of
The head 10 comprises a series of nozzles which are offset parallel to the longitudinal direction L, for example 8 nozzles which are labeled 1 to 8 in
The substance to be deposited on the medium 100 may be any substance compatible with the nozzle technology. It may be ink, a transparent refractive substance, a liquid crystal, a substance that is active electrochemically or when irradiated, lithographic resin, etc. It may be in the form of a liquid, a gel, a powder, or a heterogeneous phase.
During a preliminary step which is illustrated in
In substep /1a/, the amount of substance ejected by the nozzle i reaches the test medium 200 at the point of impact which is denoted Pi. The longitudinal deviation δli is the length of the segment connecting the perpendicular projection of the outlet of the nozzle i onto the test medium 200, to the point of impact Pi. It is defined algebraically: for example each longitudinal deviation δli is positive when oriented towards the top of the head 10, and negative when oriented towards the bottom of the head 10. In addition, the exact position of the head 10 facing the medium 100 or test medium 200 can be precisely defined in various ways. For example, the head 10 may be equipped with an optical detector 11, and the positions of the outlets of the nozzles 1, 2, 3, . . . precisely known relative to this. The detector 11 may be used to define the positions of the edges of the medium 100 or test medium 200, then the head 10 is controlled so that it moves to face a defined location of the medium 100 or test medium 200. The displacement distances of the head 10 are controlled with sufficient accuracy using a means known to a person skilled in the art.
The use of a scanner for substep /1b/ is particularly advantageous for simultaneously measuring all ejection deviations of the nozzles with a high level of precision. It is possible to increase this precision by compensating for variations in the scanning rate of the scanner in the longitudinal direction L during substep /1b/.
In a preferred implementation of the invention which will be described below, a transverse ejection deviation δti may also be measured for each nozzle i. As is shown in
The longitudinal deviations δli, and possibly the transverse deviations δti, are stored.
As shown in
Initially and for clarity in the description, it is assumed that the target points C1, C2, C3, . . . are aligned in the longitudinal direction L. It is also assumed that the transverse deviations δti are zero or that no deposition precision criterion is applied in the transverse direction T.
The head 10 is brought into alignment with the set of target points C1, C2, C3, . . . in the transverse direction T, for example near B0 at the top of the medium 100, then successive offsets of the head 10 relative to the medium 100 are ordered, parallel to the longitudinal direction L. In other words, the head 10 is moved relative to the medium 100 to reach an initial longitudinal offset of the head which is denoted l0, then in successive increments in the longitudinal direction L to reach subsequent longitudinal offsets of the head relative to the initial offset l0. All the successive increments are equal and denoted dl, l being a longitudinal coordinate indicating the position of the head 10 relative to the medium 100 in the direction L (
More generally, it is determined by computer which of the nozzles i have outputs presenting longitudinal offsets Δlij for certain target points Cj which are the opposite of the longitudinal deviations δi, for each value of the longitudinal coordinate l of the position of the head 10. Then these nozzles are selected for this value of the coordinate l, and they are saved electronically with the amounts of substance to be ejected for each nozzle selected. Nozzle selections are therefore made for all values of the longitudinal coordinate l which are equal to n×dl, n being an integer. This process is continued, for example from the top to the bottom of the medium 100.
Then the head 10 is placed facing the medium 100 at the initial offset l0 of the head then successively at the longitudinal offsets incremented by dl. Each time, only the nozzles selected for the current value of the longitudinal coordinate l are activated to deposit portions of substance onto the medium 100, in the stored quantities.
For example, the increment dl may be equal to 10 μm, or 1 μm, particularly when the nozzle outlets are separated by 169 μm in the longitudinal direction L.
Preferably, the increment dl may be a divisor of a longitudinal step distance for the head 10 which corresponds to a distance between extreme nozzles of the head 10 which are longitudinally opposite in direction L, while being less than the distance between two neighboring nozzles in the same direction L. Two different nozzles of the head 10 may then respectively deposit portions of the substance at the same target point on the medium 100, at two different positions of the head 10 in the direction L, for example to obtain a higher contrast. The longitudinal step distance for the head 10 is also the distance the head 10 is shifted in direction L, so that the outlet of nozzle 1 arrives at dl below the outlet of nozzle 8. These two positions of the head 10 then allow depositing the substance onto the medium 100 in a segment parallel to the direction L, with a density of deposited substance which is constant along the segment.
For most applications of the invention, the substance must be deposited at locations on the medium 100 which are offset from each other not only in the longitudinal direction L but also in the transverse direction T. In this case, the head 10 is moved in the two directions T and L facing the medium 100. Such a two-dimensional displacement can be achieved by moving the head 10 in the transverse direction T, from each position of the head 10 successively offset by the increment dl in the longitudinal direction L as described above.
When the transverse ejection deviations δt1, δt2, δt3, . . . have been measured, they can be compensated for by activating each nozzle selected for the longitudinal offset from a path, at a selected moment during the travel along this path. This moment is when the nozzle has a transverse offset relative to a target point which is opposite the transverse deviation of the nozzle concerned. In this manner, the amount of substance is deposited exactly at the target point, with no perceptible deviation between the point of impact and the target point in the two directions T and L. In general, the travel along each of the paths T1, T2, T3, . . . occurs in a continuous movement of the head 10, and the selected nozzle is activated during this movement without stopping the head.
When the deposition area on the medium 100 is longer in the longitudinal direction L than the distance between the nozzles 1 and 8 of the head 10 in the same direction L, the sequence of longitudinal offsets of the head 10 which has been described, using the increment dl, is continued with the nozzle 1 in the subsequent positions of the head 10 beyond the initial position of the nozzle 8 (see the subsequent position of the head 10 represented with dotted lines in
In particular, the invention allows making deposits of a uniform density of the amount of substance deposited, to cover large surface areas.
In general, a compromise may be searched for between a value of the increment dl for the longitudinal offset of the head 10 which is not too low, and an accepted tolerance for the accuracy of the coincidence between the points of impact and the target points in the longitudinal direction L. The number of transverse paths can thus be reduced to the value necessary to obtain the desired deposition quality throughout the deposition area. Such a compromise can be found automatically using optimization software, based on initially measured values for the longitudinal ejection deviations of all the nozzles.
It is understood that the invention may be applied to a head 10 which comprises several columns of nozzles, as represented in
Depositions have been made on media 100 as represented in
Number | Date | Country | Kind |
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10 52322 | Mar 2010 | FR | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/FR2011/050601 | 3/22/2011 | WO | 00 | 9/25/2012 |
Publishing Document | Publishing Date | Country | Kind |
---|---|---|---|
WO2011/121209 | 10/6/2011 | WO | A |
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20130016159 A1 | Jan 2013 | US |