Patent Application
20130201235
The present invention relates to inkjet printing. It finds particular application in conjunction with increasing resolution of inkjet printing and will be described with particular reference thereto. It will be appreciated, however, that the invention is also amenable to other applications.
In traditional inkjet technology, image quality is related to the volume of individual ink droplets. With all else being equal, a smaller drop volume results in higher resolution and better image quality. For example, a drop volume for a 600 dpi×600 dpi resolution inkjet printer is about 16.0 pL, while that for a higher quality 1200 dpi×1200 dpi resolution inkjet printer is only about 4 pL. Sub-picoliter drops are required to obtain printed images at greater than 2400 dpi×2400 dpi resolution.
Printheads capable of producing sub-picoliter drops are challenging to manufacture. More specifically, extremely small orifice holes are needed to achieve such sub-picoliter drops. The dimensional accuracy and uniformity of such orifice holes is beyond the capability of existing micro fabrication technologies. Moreover, it is difficult to operate a printhead with small drop volumes due to problems such as jet straightness. In addition, small orifices tend to become clogged more easily by contaminants. Small orifices also have short latency and are difficult to recover after being idle for a period of time.
Due to finite size of spots made by inkjet droplets on the receiving substrate, a halftoning technique is used to produce various levels of gradation for mid-tone shades. Smaller drop volumes achieve higher image quality by producing a finer level of gradation in the mid-tone shades without introducing objectionable graininess or other noises associated with halftoning. Halftoning also reduces the printing speed due to the required processing time for rendering the halftone image.
Another approach for increasing color image quality uses diluted inks. Because less colorant is present in each diluted ink drop, the effect of smaller drops having higher concentration is achieved. However, certain drawbacks to this approach include a higher cost and more complex printing system, issues related to drying, and media cockle due to excess solvents.
The present invention provides a new and improved apparatus and method which addresses the above-referenced problems.
According to one aspect of the invention, a method of ejecting liquid droplets includes providing a printhead operable to eject liquid drops having a plurality of drop volumes Vi, for i equal to 1 through n, where n≧2, with Vj>Vi when j>i. One of the plurality of drop volumes is a minimum drop volume Vmin, and the difference in drop volume between successively larger drops is less than Vmin—i.e., δk, k+1=Vk+1−Vk<Vmin for k equal to 1 through n−1. The method also includes ejecting liquid drops through the printhead.
According to another aspect of the invention, a method of ejecting ink droplets includes providing a printhead operable to eject liquid drops having a plurality of drop volumes, each of the plurality of drop volumes being ejectable from distinct nozzles, one of the plurality of drop volumes being a minimum drop volume Vmin, another of the plurality of drop volumes being a maximum drop volume Vmax that is less than two times the minimum drop volume Vmin; and ejecting liquid drops through the printhead.
According to another aspect of the invention, a method of ejecting ink droplets includes providing a printhead operable to eject liquid drops having a plurality of drop volumes, a first of the drop volumes being a minimum drop volume Vmin, respective increments between adjacent drop volumes being <Vmin; and ejecting liquid drops through the printhead.
According to another aspect of the invention, a liquid ejecting apparatus, includes a printhead including a first liquid ejector and a second liquid ejector. The first liquid ejector is operable to eject liquid drops having a first drop volume, which is a minimum drop volume. The second liquid ejector is operable to eject liquid drops having a second drop volume which is greater than the minimum drop volume, an increment between the first and second drop volumes being less than the minimum drop volume.
In the accompanying drawings which are incorporated in and constitute a part of the specification, embodiments of the invention are illustrated, which, together with a general description of the invention given above, and the detailed description given below, serve to exemplify the embodiments of this invention.
With reference to
The electronic signals are transmitted from the controller 20 to an electrical pulse generator 32. The pulse generator 32 transmits an electronic signal to the ink jet printhead 26 for causing one of the drops 24a, 24b, 24c of a particular volume to be ejected from the printhead 26. Ink is supplied to printhead 26 from fluid source 18 through ink passageway 38. The printhead 26 includes liquid ejectors 34 for ejecting the drops 24a, 24b, 24c of ink. Each of the ejectors 34 includes a nozzle 36, a liquid chamber 40 in fluid communication with ink passageway 38 as well as nozzle 36, and a drop forming mechanism 42 operatively associated with the nozzle 36. The electronic signal from the pulse generator 32 causes the drop forming mechanism 42 to excite ink in the liquid chamber 40 such that the ink is ejected from the printhead through the nozzle 36. A size of the drop 24 ejected from the nozzle 36 is proportional to a desired color level (e.g., grey level) of the color at the particular pixel 12 in the image 14.
In the illustrated embodiment, the printhead 26 includes a plurality of nozzles 36a, 36b, 36c having different nozzle diameters (e.g., three (3) different nozzle diameters). Ink drops ejected from a nozzle with a relatively larger diameter are larger relative to ink drops ejected from a nozzle with a relatively smaller diameter. Although geometrical differences between drop generators (such as nozzle size) is one way to produce different drop volumes, for some types of inkjet printing, the size of the drop forming mechanism or the waveform of the pulse applied to the drop forming mechanism can also provide a range of different drop volumes. The electronic signals from the controller 20, and optionally also logic circuitry (not shown) incorporated in the printhead, determine which of the nozzle(s) 36a, 36b, 36c eject the ink onto the pixel 30 on the received medium 22. More specifically, a first electronic signal is generated if a drop of a first diameter is desired from the nozzle 36a; a second electronic signal is generated if a drop of a second diameter is desired from the nozzle 36b; and a third electronic signal is generated if a drop of a third diameter is desired from the nozzle 36c. The nozzles 36a, 36b, and 36c are all connected to the same fluid source 18 in the example of
In the embodiment illustrated in
Traditionally, a drop volume of ≦1 pL is required to produce the smooth gradation of color tones that is characteristic of a 2,400×2,400 dpi quality print.
In one embodiment, it is contemplated that the three (3) drop volumes produced by the respective nozzles 36a, 36b, 36c are 2.0 pL, 2.67 pL, and 3.33 pL. In other words, the minimum drop volume in this example is Vmin=2.0 pl. The difference between the middle drop volume and the minimum drop volume is 0.67 pl, which is less than Vmin. Similarly, the difference between the largest drop volume and the middle drop volume is also 0.67 pl, which is less than Vmin. Using notation δk,k+1 to denote the difference in drop volume between the kth size drop and the next size larger drop (k+1), δ1,2=2.667−2.0=0.67 pl and δ2,3=3.333−2.667=0.67 pl in this example. If up to two (2) drops of each of the three (3) volumes may be ejected for each pixel in a 600 dpi×600 dpi grid, a total of six (6) drops may be printed in each pixel. Therefore, a total of 16.0 pL may be ejected onto each pixel of the printing medium 22.
Column 1 in Table 1 represents the number of different levels of ink coverage (or gray levels or color levels) achieved by the various combinations of drop volumes identified in Column 2. The numbers in the first row of columns 3-5 (i.e., Vol 1 (V1), Vol 2 (V2), and Vol 3 (V3)) represent the three (3) different respective drop volumes (i.e., 2.000 pL, 2.667 pL, and 3.333 pL). In this embodiment, the incremental volumes between the drops δdvol are uniform (i.e., 0.67 pL). The numbers in the body of the table for columns 3-5 represent numbers of drops per pixel for each of the respective drop volumes. Column 6 represents the total volume of ink deposited on a pixel. Column 7 represents the increment Δ of total ink volume per pixel between the current and previous color levels.
The drop volumes are chosen to satisfy the following conditions to provide uniform mid-tone increments:
2(V1+V2+V3)=16.0pL
V1=Vmin
V2=Vmin+δdvol
V3=Vmin+2δdvol
2V1=Vmin+3δdvol
The solution gives δdvol=0.67 pL and Vmin=2.0 pL. In the illustrated embodiment, δdvol is less than Vmin. In addition, V2<2V1 and V3<2V1. Also, V2−V1=V3−V2.
As seen in Table 1, six combinations (i.e., 8, 11, 13, 16, 18, and 21) result in redundant color levels. Such redundant volume levels are beneficial in the sense that if one of the nozzles 36 of the printhead 26 is not usable (e.g., clogged), an alternate combination may be utilized to achieve the desired total volume level.
Because of the redundant color levels, twenty-one (21) different levels may be achieved with a uniform incremental volume per pixel Δ of ˜0.67 pL in the mid-tone range (12.5% to 87.5% coverage) (i.e., between levels 2 and 20). In the present example, since the increment Δ of total ink volume per pixel between each of the adjacent levels is uniform (e.g., 0.67 pL) in the mid-tone range, an equivalent resolution of 2,940 dpi×2,940 dpi can be achieved. More specifically, if δdvol=0.67 pL, then 23.988 (i.e., 16.0 pL/0.667 pL) levels per pixel are possible. Therefore, the resolution of a 600 dpi×600 dpi grid is increased by 4.8987 (i.e., 23.9881/2) to ˜2,940 dpi×2,940 dpi.
Generally, the printhead 26 is operable to eject liquid drops having a plurality of drop volumes Vi, for i equal to 1 through n, where n≧2, with Vj>Vi when j>i. One of the plurality of drop volumes is the minimum drop volume V1=Vmin, and δk, k+1=(Vk+1−Vk)<Vmin, for k equal to 1 through n−1. In the example described above corresponding to Table 1, n=3, but n can be greater than 3 in some embodiments. In addition, in the example described above, δ1,2=0.67 pl=δ2,3, i.e. δk, k+1=δk+1, k+2 in this example for k equal to 1 through n−2, but in some embodiments the differences in drop volumes between successively larger drops is not always the same.
Fabricating a printhead to produce a minimum drop volume (Vmin) of 2.0 pL (which requires a nozzle of ˜9.8 μm) is more feasible than fabricating a printhead to produce a minimum drop volume of 0.67 pL (which requires a nozzle of ˜5.7 μm). Thus, the present invention is advantageous for providing an equivalent smoothness of gradation in gray levels, while not requiring such a small nozzle diameter.
With reference to
With reference to Table 2, additional color levels may be achieved if the incremental volumes between the drops δdvol is not uniform.
In Table 2, the drop volumes are chosen to satisfy the following conditions:
2(V1+V2+V3)=16.0pL
V1=Vmin
V2=Vmin+2δdvol
V3=Vmin+3δdvol
2V1=Vmin+5δdvol
The solution gives δdvol=0.40 pL and Vmin=2.0 pL. In the illustrated embodiment, δdvol is less than Vmin. In addition, V2<2V1 and V3<2V1. In Table 2, (V2−V1)≠(V3−V2), i.e. δ1,2≠δ2,3.
As seen in Table 2, twenty-seven (27) different levels may be achieved with a uniform incremental volume per pixel Δ of ˜0.4 pL in the mid-tone range (30% to 70% coverage) (i.e., between levels 3 and 25). In the present example, since the increment Δ of total ink volume per pixel between each of the adjacent levels is uniform (e.g., 0.4 pL) in the mid-tone range, an equivalent resolution of 3,795 dpi×3,795 dpi can be achieved. More specifically, if δdvol=0.40 pL, then 40.0 (i.e., 16.0 pL/0.40 pL) levels per pixel are possible. Therefore, the resolution of a 600 dpi×600 dpi grid is increased by 6.3246 (i.e., 401/2) to ˜3,795 dpi×3,795 dpi.
Generally, the printhead 26 is operable to eject liquid drops having a plurality of drop volumes Vi, for i equal to 1 through n, where n≧2, with Vj>Vi when j>i. (In other words, in this numbering convention for the different drop volumes, the larger the subscript, the larger the drop volume.) One of the plurality of drop volumes is the minimum drop volume V1=Vmin, and δk,k+1=(Vk+1−Vk)<Vmin, for k equal to 1 through n−1. In addition δk, k+1≠δk+1, k+2, for some k for examples of the type corresponding to Table 2. Therefore, Vk+1−Vk, for k equal to 1 through n−1, is not substantially uniform for some value of k.
With reference to
Traditionally, a drop volume of ≦0.36 pL is required to produce a 4,000×4,000 dpi quality print.
In another embodiment, a printhead contains nozzles of four (4) different diameter sizes that eject drops of four (4) different volumes (e.g., 1.45 pL, 1.82 pL, 2.18 pL, and 2.55 pL). Up to two (2) drops of each volume (i.e., a total of eight (8) drops) can be printed to obtain 16.0 pL on each of the pixels of a 600 dpi×600 dpi grid.
With reference to Table 3, eight-one (81) different combinations of drop volumes are possible.
Column 1 in Table 3 represents the number of different gray levels (i.e., 39 levels having distinctly different ink volume per pixel) achieved by the various combinations (see column 2) of drop volumes. The numbers in the first row of columns 3-6 (i.e., Vol 1 (V1), Vol 2 (V2), Vol 3 (V3), and Vol 4 (V4)) represent the four (4) different respective drop volumes (i.e., 1.450 pL, 1.815 pL, 2.180 pL and 2.545 pL). In this embodiment, the incremental volumes between the drops δdvol are substantially uniform (i.e., ˜0.365). The numbers in the body of the table for columns 3-6 represent numbers of drops per pixel for each of the respective drop volumes. Column 7 represents the total volume of ink deposited on a pixel. Column 8 represents the increment Δ of total ink volume per pixel between the current and previous combinations.
It is to be noted in Table 3 that 42 of the combinations result in redundant (not unique) total volume levels (see Vol/Pxl in column 7).
The drop volumes are chosen to satisfy the following conditions to provide uniform mid-tone increments:
2(V1+V2+V3+V4)=16.0pL
V1=Vmin
V2=Vmin+δdvol
V3=Vmin+2δdvol
V4=Vmin+3δdvol
2V1=Vmin+4δdvol
The solution gives δdvol=0.365 pL and Vmin=1.45 pL. In the illustrated embodiment, δdvol is less than Vmin. In addition, V2<2V1, V3<2V1, and V4<2V1. In Table 3, V4−V3=V3−V2=V2−V1.
As seen in Table 3, the thirty-nine (39) different color levels may be achieved with a uniform incremental volume per pixel Δ of ˜0.365 pL in the mid-tone range (9% to 91% coverage) (i.e., between levels 2 and 38). In the present example, since the increment Δ of total ink volume per pixel between each of the adjacent levels is substantially uniform (e.g., ˜0.365 pL) in the mid-tone range, an equivalent resolution of 3,973 dpi×3,973 dpi can be achieved. More specifically, if δdvol=0.365 pL, then 43.8356 (i.e., 16.0 pL/0.365 pL) levels per pixel are possible. Therefore, the resolution of a 600 dpi×600 dpi grid is increased by 6.6208 (i.e., 43.83561/2) to ˜3,973 dpi×3,973 dpi.
Fabricating a printhead to produce a minimum drop volume (Vmin) of 1.45 pL (which requires a nozzle diameter of ˜8.3 μm) is significantly more feasible than fabricating a printhead to produce a minimum drop volume of 0.365 pL (which requires a nozzle diameter of ˜4.2 μm).
In another embodiment, a printhead containing nozzles of four (4) different diameters sized to eject drops of four (4) different volumes such that increments between the volumes (e.g., 1.50 pL, 1.75 pL, 2.25 pL, and 2.75 pL) ejected from adjacent nozzles (e.g., 8.5 μm, 9.2 μm, 10.4 μm, and 11.5 μm) are not uniform. Up to two (2) drops of each volume (i.e., a total of eight (8) drops) can be printed to obtain 16.5 pL on each of the pixels of a 600 dpi×600 dpi grid.
With reference to Table 4, at least fifty-three (53) different combinations of drop volumes are possible.
Column 1 in Table 4 represents the number of different color levels (i.e., 53 levels) achieved by the various combinations (see column 2) of drop volumes. The numbers in the first row of columns 3-6 (i.e., Vol 1 (V1), Vol 2 (V2), Vol 3 (V3), and Vol 4 (V4)) represent the four (4) different respective drop volumes (i.e., 1.50 pL, 1.75 pL, 2.25 pL and 2.75 pL). In this embodiment, not all of the incremental volumes between the drops δdvol are substantially uniform. The numbers in the body of the table for columns 3-6 represent numbers of drops per pixel for each of the respective drop volumes. Column 7 represents the total volume of ink deposited on a pixel. Column 8 represents the increment Δ of total ink volume per pixel between the current and previous combinations.
It is to be noted in Table 4 that 28 of the combinations result in redundant (not unique) total volume levels (see Vol/Pxl in column 7).
The drop volumes are chosen to satisfy the following conditions to provide uniform mid-tone increments:
2(V1+V2+V3+V4)=16.5pL
V1=Vmin
V2=Vmin+δdvol
V3=Vmin+3δdvol
V4=Vmin+5δdvol
2V1=Vmin+6δdvol
The solution gives δdvol=0.25 pL and Vmin=1.50 pL. In the illustrated embodiment, δdvol is less than Vmin. In addition, V2<2V1, V3<2V1, and V4<2V1. In Table 4, V4−V3=V3−V2. However, neither V4−V3 nor V3−V2 equals V2−V1.
As seen in Table 4, the fifty-three (53) different color levels may be achieved with a uniform incremental volume per pixel Δ of ˜0.25 pL in the mid-tone range (16.7% to 83.3% coverage) (i.e., between levels 5 and 49). In the present example, since the increment Δ of total ink volume per pixel between each of the adjacent levels is substantially uniform (e.g., ˜0.25 pL) in the mid-tone range, an equivalent resolution of 4,874 dpi×4,874 dpi can be achieved. More specifically, if δdvol=0.25 pL, then 66.0000 (i.e., 16.5 pL/0.25 pL) levels per pixel are possible. Therefore, the resolution of a 600 dpi×600 dpi grid is increased by 8.1240 (i.e., 66.00001/2) to ˜4,874 dpi×4,874 dpi.
In a color printer capable of printing three (3) colors (e.g., cyan, magenta, yellow (CMY)), a total of 148,877 colors may be achieved at each pixel by combining the fifty-three (53) levels (see Table 4) of each of the three (3) colors. As discussed above, only eight (8) possible colors are achieved from a single drop per pixel binary printing operation and 729 possible colors are achieved from eight (8) drop per pixel printing operation using a single drop size.
It is to be understood that the number of different drop volumes (which are produced by a printhead having nozzles of different diameters), the numbers of drops per pixel for each volume, and the pixel grids described in the various embodiments discussed above are merely examples. Other embodiments having different drop volumes, numbers of drops of pixel for each volume, and pixel grids are also contemplated.
In addition, it is also contemplated that the drops of ink for each drop volume may be printed by the same nozzle or by different nozzles.
In each of the embodiments discussed above, the maximum drop volume Vmax is less then twice the minimum drop volume Vmin. For example, with reference to Table 1, the minimum drop volume Vmin is 2.0 pL and the maximum drop volume Vmax is 3.33 pL. In Table 2, the minimum drop volume Vmin is 2.0 pL and the maximum drop volume Vmax is 3.2 pL. In Table 3, the minimum drop volume Vmin is 1.45 pL and the maximum drop volume Vmax is 2.55 pL. In Table 4, the minimum drop volume Vmin is 1.50 pL and the maximum drop volume Vmax is 2.75 pL. In addition, the increments between the adjacent drop volumes are less than the minimum drop volume Vmin.
With reference to Table 5, a given number of drops per pixel (Drops/Pxl)/total number of possible drop volume combinations (#comb) for a pixel depends on the available number of different drop sizes (#DV) and the number of drops for each drop size ejected onto the pixel (#drops/DV). As seen in Table 5, higher numbers of combinations are achieved with a maximum number of different drop sizes.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the scope of the invention.
This is a divisional application of U.S. patent application Ser. No. 12/179,788 filed Jul. 25, 2008.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12179788 | Jul 2008 | US |
| Child | 13763629 | US |
