1. Field of the Invention
The present invention relates to an inkjet printing device and an inkjet printing method.
2. Description of the Related Art
When an ink discharge port provided in a print head of an inkjet printing device is not used for a long time, an ink solvent within the ink discharge port evaporates and thus the viscosity of the ink can be increased. In this case, even when a drive signal is applied to an element that produces energy utilized for discharging the ink, the ink is not properly discharged, and this causes a discharge failure such as variations in the direction in which the ink is discharged, an insufficient amount of ink discharged or unsuccessful discharge, with the result that it may be impossible to acquire a desired image. In order to eliminate the cause of the above-described discharge failure and acquire the satisfactory ink discharge performance of the print head, for example, an operation referred to as a preliminary discharge is often performed. Specifically, the preliminary discharge is an operation of driving an element that produces energy utilized for discharging ink and thereby discharging the ink so as to release from a discharge port the ink in a state where part of a volatile component evaporates and thus the discharge performance and the printing quality are unsatisfactorily acquired. The preliminary discharge is an operation that is different from a printing operation of forming an objective image and that copes with the discharge failure resulting from the evaporation of an ink solvent; when the preliminary discharge is performed on a print medium, an image is consequently printed. Japanese Patent Application Laid-Open No. 2008-213471 proposes a method for performing a preliminary discharge in a predetermined position of a print medium.
Incidentally, in inkjet printing, in general, as a larger amount of ink is discharged on a print medium, the degree of color reproduction of an image can be increased. However, if an amount of ink that exceeds the ink absorption performance of the print medium is discharged, the ink that is not fully absorbed into the print medium can cause so-called bleeding such as ink blurring or uneven mixing in images. Moreover, a problem such as a stain may occur in which an excessively larger amount of ink overflows the print medium, adheres to a transport unit and is transferred to a print medium. In order to solve these problems, there is conventionally proposed a printing method in which the amount of ink per unit area used for the formation of an image is previously set based on an upper limit for the amount of ink per unit area that does not cause a problem such as bleeding (for example, see Japanese Patent Application Laid-Open No. 2005-125602).
However, since the preliminary discharge is not a printing operation for the formation of an image for the purpose of printing, part of a print medium where an image is printed by the preliminary discharge becomes unnecessary trash, and this increases the cost of printing. If the preliminary discharge is performed in a smaller area on the print medium to reduce the cost, a necessary number of discharges to eliminate the discharge failure of a nozzle may cause an amount of ink exceeding its ink absorption performance to be supplied to the area of the print medium.
To overcome these problems, an object of the present invention is to provide an inkjet printing device and an inkjet printing method that can perform printing in which an area of a print medium used by a preliminary discharge is minimized and in which ink that is not absorbed into the print medium and causes a problem such as a stain is not produced.
To achieve the object, an inkjet printing device according to the present invention that performs printing on a print medium with a print head including a nozzle for discharging ink, includes: a transport unit transporting the print medium; a printing unit discharging the ink from the print head while the transport unit transports the print medium, such that the printing unit prints an image for printing on the print medium and an image formed by a preliminary discharge; a first limiting unit limiting an amount of ink to be discharged per unit area of the print medium based on image data on the image for printing such that the amount of ink per unit area is equal to or less than an upper limit Alim; and a second limiting unit limiting an amount of ink to be discharged per unit area of the print medium for the image formed by the preliminary discharge such that the amount of ink per unit area is more than the upper limit Alim but is equal to or less than an upper limit Blim.
According to the present invention, it is possible to provide an inkjet printing device that can print both the objective image that satisfies bleeding performance and the preliminary discharge image that causes no stain in a transport unit resulting from the overflow of ink. Thus, it is possible to reduce the quantity of print media consumed.
Further features of the present invention will become apparent from the following description of exemplary embodiments (with reference to the attached drawings).
Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.
In order to achieve the original purpose of the preliminary discharge to release ink having high viscosity resulting from evaporation, it is preferable to discharge ink from all the nozzles a predetermined number of times. In order to achieve an object of the present invention to reduce the consumption of the print medium, it is preferable to perform the preliminary discharge with a larger amount of ink per unit area of the preliminary discharge image 12. From the standpoint described above, the inventors of the present invention have examined a device and a method for reducing the consumption of a print medium.
Here, what is important is that, although in the printing of the objective image, an upper limit for the amount of ink discharged onto the print medium exists in terms of image quality, especially bleeding such as ink blurring in images, bleeding is permissible because the preliminary image finally becomes trash. Hence, when an upper limit for the amount A of ink per unit area that can be used for printing the objective image, that is, that satisfies the bleeding performance of the image is set to be “Alim”, the amount B of ink per unit area that exceeds the upper limit Alim can be used for printing the preliminary discharge image. On the other hand, when a significantly large amount of ink is discharged for the preliminary discharge image, a problem such as a stain occurs in which ink that is not absorbed and that overflows the print medium adheres to a transport unit such as the transport roller and is transferred to the print medium. In order to cope with this problem, it is necessary to additionally set an upper limit Blim (upper limit Blim>upper limit Alim) for the amount B of ink per unit area that prevents the adherence of ink to the transport unit and the stain of the print medium resulting from the transfer of the adhered ink.
As described above, in the present invention, the amount of ink per unit area that is larger than the upper limit Alim, that is, the upper limit amount A of ink causing no bleeding in the image of the print medium but is equal to or less than the upper limit Blim causing no stain of the transport unit and print medium resulting from ink overflow is used for the printing of the preliminary discharge image.
In the present invention, the amount of ink per unit area of the print medium for the objective image and the preliminary discharge image can be regulated by controlling the discharge of ink on the print medium by the inkjet printing device based on the “print duty”. In the present specification, the “print duty” is specified as a ratio (unit:%) of the amount of ink actually used for the printing with reference to the state in which an amount of ink of a predetermined volume is discharged in a unit area on the print medium. The “predetermined volume” is a preset constant volume; for example, it can be the volume of ink when printing is performed by executing one ink discharge for one pixel. In the present embodiment, as the “predetermined volume”, an ink amount of 8.6 μl/square inch (corresponding to eight ink discharges to a pixel of 600 dpi when the volume of an ink drop is 3 pl) is employed.
The inkjet printing device and the inkjet printing method of the present invention will be described in detail with reference to
The printing of the objective image will first be described among the printing of the objective image and the preliminary discharge image. The printing of the objective image is performed with the amount of ink per unit area that is equal to or less than the upper limit Alim for the amount of ink per unit area that causes no bleeding in the image of the print medium. A print duty for achieving the amount Alim of ink per unit area is set to be Dlim (%). The Dlim (%) is an upper limit for a print duty D (%) for performing printing without bleeding being caused on an image. The upper limit Alim or Dlim depends on ink used and quality such as the absorption of ink into the print medium, and is basically characteristic of the print medium. Hence, upper limits Dlim for various print media intended to be used for the inkjet printing device are determined by previously performing printing tests using various print duties D for the print media and visually checking whether or not bleeding occurs.
In order for the objective image 13 to be printed, at the upper limit setting unit 10 of the inkjet printing device, an upper limit Dlim (%) of the print duty on the print medium 3 used is first input (step S1). On the other hand, image data on the objective image 13 are input at the image data input unit 6, for example, as an input value R1 of 256-level gradation of 8 bits per pixel. In the above description, the upper limit Dlim of the print duty and the image data R1 are input in this order; the present invention is not limited to this order in which they are input.
The image data processing unit 7 references an upper limit conversion table that is previously determined according to the upper limit Dlim which has been input, and corrects the input value R1 for the image data on each pixel to a correction value R2. This correction is performed so as to prevent bleeding from being caused in printing within the output setting range of the inkjet printing device. A description will be given showing an example of the upper limit conversion table in
Then, the image data processing unit 7 converts the value R2 into binary data corresponding to the discharge signal for each of the nozzles 11 in the head, and outputs the binary data to the control unit 9 (step S4). When the value R2 is converted into the binary data, the conversion is performed such that values R2 ranging from 0 to 255 correspond to print duties ranging from 0% to 150%. In
Then, the method of printing the preliminary discharge image will be described. The printing of the preliminary discharge image is performed by using the amount B of ink per unit area that is equal to or less than the upper limit Blim for the amount of ink per unit area that causes no stain in a transport means and a print medium resulting from the overflow of ink. The print duty for achieving the amount Blim of ink per unit area is set to be Dblim (%). Dblim (%) is an upper limit of the print duty for performing printing that causes no stain in a transport means and the like. The upper limit Blim or Dblim depends on ink to be used and quality such as the absorption of ink into the print medium, and is basically characteristic of the print medium. Hence, the upper limits Dblim for various print media intended to be used for the inkjet printing device are determined by previously performing printing tests by using various print duties for the respective print media and visually checking whether or not bleeding occurs.
The relationship between the print duty and the image data which are used in the printing of the preliminary discharge image will now be described. The printing of the preliminary discharge image on the print medium is performed so as to restore the nozzles. Hence, the image data on the preliminary discharge image is preferably data which specifies the quantity of discharges of ink printed in the pixel corresponding to each of the nozzles such that the nozzles each release the same number of discharges of ink. In this example, as described above, as the predetermined volume, which is a reference for the print duty, an ink amount of 8.6 μl/square inch (corresponding to eight ink discharges to a pixel of 600 dpi when the volume of an ink drop is 3 pl) is employed. If a nozzle pitch (resolution) is set as 120 dpi, when the preliminary discharge image of, for example, 100% print duty is printed, image data for releasing four ink drop discharges per each of the nozzles to the pixels of 600 dpi is used. When the preliminary discharge image of, for example, 175% print duty is printed, image data for releasing seven (=4×175÷100) ink discharges per each of the nozzles to each of the pixels is used.
As described above, the upper limit Dblim (%) of the print duty for various print media used in the inkjet printing device and the corresponding preliminary discharge image data are previously determined, and are stored in the preliminary discharge image data storage unit 8 of the inkjet printing device.
In the printing, the upper limit Dblim (%) of the print duty for the print medium to be used is input at the upper limit setting unit 10 of the inkjet printing device (step S1). In the printing operation, the control unit 9 selects the preliminary discharge image data corresponding to the upper limit Dblim (%) of the print duty that has been input from the print duties and the preliminary discharge image data previously stored in the preliminary discharge image data storage unit 8 (step S5).
As described above, based on the image data on the objective image that is output from the image data processing unit 7 to the control unit 9 and the image data on the preliminary discharge image selected by the control unit 9, the control unit 9 controls the discharge operation of the print head 2K and the driving of the transport rollers 5 (step S6). In this way, each of the objective image and the preliminary discharge image is printed by the discharge of ink in predetermined positions of the print medium in the same order in which the images are formed on the print medium (step S7).
In order to minimize the quantity of print media used in the printing of the preliminary discharge image, it is most preferable to use the upper limit Dblim (%) as the print duty used in the actual printing. In this example, the setting is performed as described above. However, it is easily understood that, when the print duty is set such that the print duty is more than the upper limit Dlim of the print duty causing no bleeding and is equal to or less than the upper limit Dblim of the print duty causing no stain in a transport unit and the like, it is possible to achieve an object of the present invention, that is, the reduction of the quantity of print media.
As described above, the preliminary discharge image is printed using a print duty D (≦Dblim) (%) higher than the possible upper limit Dlim (%) of the print duty for the objective image and thus, it is possible to reduce the quantity of print medium consumed as compared with the case where printing is performed using Dlim (%).
Although the first embodiment shows the example in which the inkjet printing device includes the print head having one array of nozzles, the present invention can also be applied to an inkjet printing device having a plurality of arrays of nozzles. An example of an inkjet printing device including a print head having two arrays of nozzles will be described below. For ease of description, the constituent elements of the inkjet printing device, except the print head, of the second embodiment are the same as in the first embodiment (see
In
However, even in the case of any number of arrays of nozzles, the same effects of the present invention as in the case of one array of nozzles are acquired. In other words, in the printing of the preliminary discharge image, when a print duty D (≦Dblim) (%) higher than the upper limit Dlim (%) of the print duty for the objective image is employed, it is possible to reduce the quantity of print medium consumed as compared with the case where Dlim (%) is employed.
Although the first and second embodiments deal with an example where the inkjet printing device includes one print head, the present embodiment deals with an example where a plurality of print heads are used.
When a plurality of print heads are included, it is possible to achieve the following improvements in the method of printing the preliminary discharge image, and thus the printing of the preliminary discharge image can be performed using a higher print duty. Consequently, it is possible to further reduce the length of the print medium consumed for the printing of the preliminary discharge image, that is, the preliminary discharge. A detailed description will be given below.
With respect to the print medium used in an example shown in
By contrast, in
For example, the discharge of the ink to be performed in the area having a length of one fourth of L1 in
The inventors of the present invention have found that, in the pattern of
The upper limit of the sum print duty Ds (%) can be determined by performing printing tests in the printing pattern of
As described above, by the printing method of the present invention in which the discharges from a plurality of print heads are performed in the common area, it is possible not only to prevent a stain in the transport means or the like but also reduce the length of the print medium consumed by the preliminary discharge image as compared with the case where the discharge is performed in the specific areas that differ for each of the print heads.
In the present embodiment, the example of the inkjet printing device including a plurality of print heads is shown. In the inkjet printing device including a plurality of arrays of inks in one print head as in the second embodiment, the printing pattern of the preliminary discharge image where the discharges from the overlapping arrays of inks are performed in the common large area is employed, and thus it is possible to reduce the length of the print medium consumed.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2010-141659, filed Jun. 22, 2010, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2010-141659 | Jun 2010 | JP | national |