The invention relates to the field of printing using a printhead carrying a plurality of nozzles, and more particularly to the correction or compensation of printing defaults which may be introduced by faulty nozzles.
Printing may be achieved by a broad variety of methods, some of which using a nozzle carrying printhead, whereby the nozzles eject drops of ink onto a media to built a picture onto the media. Such printing systems are typically provided with systems controlling the nozzles in order to obtain the desired result. There is a tendency to increase the number of nozzles and the concentration of nozzles placed on a printhead in order to increase both printing speed and printing definition. At the same time, the manufacturing costs of a printhead need to be maintained as low as possible, in particular in case of a disposable printhead which is meant to be replaced at the end of its lifetime. The combination of these factors means that some nozzles may become faulty. Faulty nozzle may negatively impact the quality or the speed of printing.
There are known methods of compensating faulty nozzles. A first method is disclosed for example in U.S. Pat. No. 6863361 which consists in compensating a faulty nozzle using neighboring nozzles. An embodiment of this method is illustrated on
The object of the invention is to improve a method of the type set forth such that the impact on quality and/or speed of printing is minimized. This object is achieved in a first aspect by a method of printing on a media comprising:
The invention relates to printing on a media. The media used is typically a sheet of paper, which may be a laminate, and may also be made of or comprise plastic resins or textile fibers, woven or non woven. The media may be provided in the form of a roll. The media is typically laminar, but may have a variety of shapes, for example packages such as bottles or boxes and the like. The media is typically flexible such as a sheet of paper but may also be rigid, such as card board or wood.
A printhead is provided. The printhead, sometimes also called pen, may be of the disposable type or may be a permanent printhead. The printhead may include one or more ink container, and/or may be linked by one or more conducts to one or more separated ink reservoirs. Printing is normally incremental in that the printhead is scanned over the media while firing the nozzles in order to print on the area of the media facing the printhead, the media being thereafter advanced in relation to the printhead in a direction typically perpendicular to the scanning direction, the printhead scanning the media another time while firing the nozzles on another area of the media. The printhead comprises a plurality of nozzles. In a first embodiment, the printhead comprises at least 200 nozzles. In another embodiment, the printhead comprises at least 500 nozzles. In another embodiment, the printhead comprises at least 1000 nozzles. The plurality of nozzles defines an elongated print zone. The elongated print zone comprises only the nozzles meant for printing. It should indeed be noted that in an embodiment, the printhead comprises a first plurality of nozzle and a second plurality of nozzles, whereby the first plurality comprises all nozzles of the second plurality as well as additional nozzles which are not used for printing, whereby the print zone is formed of the nozzles of the second plurality. In this embodiment, the total number of nozzles is larger than the number of nozzles of the second plurality to allow for calibration of the printhead. Such a calibration is illustrated in
According to the first aspect of the invention, at least one nozzle is faulty. A faulty nozzle may be blocked, plugged, oriented in the wrong direction etc. There are methods of detection of faulty nozzles described in the art. There may be more than one faulty nozzle. According to the invention, the faulty nozzle is a nozzle of the print zone. A faulty nozzle outside of the print zone would be of consequence for calibration purposes.
The print zone comprises one or more healthy print zones, whereby a healthy print zone is composed of a coherent group of healthy nozzles. It should be understood that a healthy zone may be formed of a single nozzle if for example all adjacent nozzles are faulty nozzles. A healthy zone does not include any faulty nozzle, and there is not any healthy nozzle adjacent a healthy zone. If a first healthy nozzle is adjacent to a second healthy nozzle, both are part of the same healthy zone. The print zone is formed of the complementary and disjoint addition of one or more faulty nozzles and of one or more healthy zones. In an embodiment, a healthy zone is formed of consecutive nozzles.
According to the first aspect of the invention, a first region of the media is submitted to N print zone passes. A pass may be in a scanning direction or in the opposite scanning direction. Any part of the first region will “see” N passes of the print zone. In an embodiment, the first region is submitted to only one print zone pass. It should be understood that the first region does not see N pass of the complete print zone. Any part of the first region is passed over only N times by some part of the print zone and is not passed more than N times by any part of the print zone. This first region corresponds to what would be called a one pass mode in the case where N=1. In an embodiment, a complete first region has a rectangular shape limited by the sides of the media perpendicular to the printhead scanning direction and by lines parallel to the scanning direction. N is a non zero positive natural integer.
According to the first aspect of the invention, a second region of media is submitted to M print zone passes. M is a positive natural integer superior to N. M is not equal to N. At least 2 of the M passes are separated by an advance of the media relative to the printhead. The N print zone passes are such that the trajectory of a faulty nozzle in one pass is followed by passing a healthy nozzle in another pass, in this order or in the inverted order. In an embodiment, N=1 and M=2.
According to the first aspect of the invention, the print is produced by alternating first and second regions.
Considering that the method according to the invention comprises printing regions submitted to a different number of print zone passes, extra flexibility is gained for compensation of faulty nozzle while minimizing the compromise in speed when compared to the methods disclosed in EP0863004 or in U.S. Pat. No. 6863361 where printing is either mono pass or multi pass and where any printed region is submitted to the same number of passes for a given print.
In an embodiment of the first aspect of the invention, the print zone has two or more healthy zones including a first healthy zone and a second healthy zone, and whereby the second healthy zone is shorter or equal to the first healthy zone, and whereby printing comprises the following steps:
In this particular embodiment, at least one faulty nozzle is located away from an end of the print zone, thus defining at least two healthy zones, at least one on each side of the faulty nozzle (or of the group of faulty nozzles). There may be more than two healthy zones. The first healthy zone is longer or equal to the second healthy zone. In a case where the first and the second healthy zone are of equal length, any may be considered the first zone, respectively second. It should be noted that the length of a healthy zone is understood as being the length along a direction perpendicular to the direction of scanning of the printhead, which normally corresponds to the direction of media displacement. The method comprises the step of advancing the media, typically using a media advance mechanism such as a roller system, a piezo system, a conveyor system, a vacuum system of a suction system for example. The method further comprises printing a swath on the media. A swath is typically a band parallel to the scan axis of the printhead having a width in the direction perpendicular to the scan axis of the print head (called “scan axis”) typically corresponding to the length of the print zone along a direction perpendicular to the scan axis. The surface area of the swath normally corresponds to the increment in printed surface area after a particular scan of the printhead. The method further comprises advancing the media of a second distance, typically in a direction perpendicular to the scan axis. In an embodiment, both the advance of the media of a first distance and of a second distance are in the same direction and in the same sense. In an embodiment, the step of advancing the media a first distance, printing a swath and advancing the media a second distance are taking place in this order. The first distance is the length of the second healthy zone, which corresponds to the maximum length of advance of the media without leaving a faulty nozzle uncovered by a further pass. The second distance is maximized in order to maximize the printing speed in that the second distance is equal to the sum of three lengths along the media displacement axis which is normally perpendicular to the scan axis being the length of the first healthy zone, the length of the second healthy zone and the length of the space separating the first and the second healthy zone. In an embodiment, the space separating or between the first and the second healthy zone only comprises one or more faulty nozzles. In another embodiment, the space separating or between the first and the second healthy zone comprises at least one further healthy zone. According to the method, the length of the longest healthy zone is smaller or equal to the average value of the second distance and of the length of the second healthy zone. The average value of the second distance and of the length of the second healthy zone corresponds to the arithmetic mean value of the first and second distances, which in turn is related to the average printing speed. This mean value is compared to the length of the longest healthy zone. If the longest healthy zone is longer or equal to this mean value, a print made using the longest healthy zone as print zone would have the same or a higher speed than the speed obtained by the method, while maintaining optimal quality as the longest healthy zone has no faulty nozzles. In an embodiment the first healthy zone is on the side of a first end of the print zone, the second healthy zone is on the side of the second end of the print zone opposite to the first end, and any or both of the first or second healthy zone is separated from the first or respectively second end by one or more healthy zones. In this embodiment, the relative position of the first and the second healthy zone is considered, whereby the order is in sequence a first end of the print zone, the first healthy zone, the second healthy zone and the second end of the print zone, considering that other healthy zones may be located in between. An end of the print zone is corresponding to an outer limit of the print zone. In this embodiment, at least one of or both of the first or second healthy zone is separated from its respectively associated end by one or more extra healthy zones. These extra healthy zones will not be used when printing, so that printing takes place without using these extra healthy zones. This is equivalent to redefining a new print zone which would exclude these extra healthy zones. In an embodiment, this is applied if a faulty nozzle continuous to an extra healthy zone could not be compensated by an extra pass without compromising printing speed in an excessive manner. In another embodiment, there is no healthy zone separating one or both of the first or second healthy zone from the first or respectively second end, which means that no extra healthy zone exist which would not be used when printing.
In another embodiment, a method according to the invention comprises a further step of compensating a faulty nozzle using one or more neighboring nozzles, a neighboring nozzle being a healthy nozzle adjacent to a faulty nozzle.
In an embodiment of the first aspect, the print zone has only one healthy zone, printing comprises the following steps:
In an embodiment of the first main aspect, a main healthy zone is identified, the main healthy zone being the longest healthy zone and the main healthy zone being longer than half the length of the print zone, whereby printing comprises the following steps:
In an embodiment of the first main aspect, printing is made by a succession of swaths, whereby each swath comprises at least part of the first region and at least part of the second region.
In an embodiment of the first main aspect, printing is made by a succession of swath, whereby each swath has a width corresponding to the length of a healthy zone.
In an embodiment of the first main aspect, each swath has a width smaller than the length of the print zone and larger that half the length of the print zone.
In an embodiment of the first main aspect, printing is made by a succession of swaths, whereby each swath differs in width from the following swath and whereby every second swaths have the same width.
The object of the invention is achieved in a second aspect by a method of printing a media using a print head having a plurality of nozzles comprising the repetition of the following cycle:
The object of the invention is achieved in a third aspect by a method of choosing a print mode for a print head comprising the following steps:
The object of the invention is achieved in a fourth aspect by a software, optionally encoded upon a machine-readable storage medium, which when executed upon a processor causes the processor to apply the method according to the third aspect of the invention. The machine readable medium may take of a variety of forms such as permanent memory, short term memory, disk, DVD, etc.
The object of the invention is achieved in a fifth aspect by a printer provided with a memory and a processor, whereby the memory comprises the software according to the fourth aspect of the invention. Such a printer would then offer print mode adapted to the position of one or more faulty nozzles in order to minimize compromise on speed or quality.
In an embodiment of the invention, a software is provided which causes a processor to apply a method consisting in choosing a particular print mode for printing using a printhead having a plurality of nozzles, at least one of which being faulty according to the invention. The printhead is itself part of a large format printer. The printhead carries 1056 nozzles, 1040 of which are part of the print zone. The nozzles are distributed in two columns, staggered. Any faulty nozzle of the print zone is detected. The method then goes on to model printing by each print mode out of a group of available print modes, the group of available print modes comprising any multi-pass print mode as described in EP863004 (hereby incorporated by reference), any one pass print mode as described in U.S. Pat. No. 6,863,361 (hereby incorporated by reference) as well as any print mode according to the present invention. Once the various print modes are modeled, the method chooses either the fastest print mode for a desired quality standard, or the highest quality achievable for a desired speed. Once the optimum print mode is defined, the media is printed using this particular print mode. It should be mentioned that a combination of print modes should also be available, for example where a print mode according to the invention would be used, whereby one (or more) particular faulty nozzle would not be compensated by another pass but using neighboring nozzles in order to increase printing speed.
Examples of print mode choices for a 1000 nozzle 2 column print zone having nozzles numbered in a manner similar to the manner illustrated in
In one example, nozzles 205, 422, 689 and 962 are faulty. The print mode chosen was: print using nozzles 1 to 961, whereby a first advance would be of 961 nozzles, and a following advance would be of 205 nozzles. With such a mode, the average printed distance per swath would be 583 nozzles. In another example, nozzles 0, 358, 828 and 919 are faulty, and the print mode chosen was to use only nozzles 1 to 827 for printing, advance once of 359 nozzles, and then of 828 nozzles, thus obtaining an average speed of 591 nozzles per swath.
From the foregoing it will be appreciated that the method provided by the invention represents a significant advance in the art. Although specific embodiments of the invention have been described and illustrated, the invention is not to be so limited. Thus, the above described embodiments should be regarded as illustrative rather than descriptive, and it should be appreciated that variations may be made in those embodiments by workers skilled in the art without departing from the scope of the invention as described in the following claims.