Patent Application
20110037799
1. Field of the Invention
The present invention relates to an inkjet printing apparatus and an inkjet printing method.
2. Description of the Related Art
In an inkjet printer, main droplets of ink are ejected from ink ejection ports of a printing head to be landed on a sheet, and in addition thereto, small droplets of ink separated from the main droplets of the ink forming the main droplets are landed on the sheet to form small dots thereon. This small dot is called “satellite”. The small droplet forming this satellite is originally ejected together with the main droplet and is formed in such a manner that a tail portion of the main droplet is generated at the back side by tension between the main droplet and a liquid surface of meniscus of an ink ejection bore and is separated from the main droplet for being in a spherical shape with surface tension. In consequence, the small droplet forming the satellite is, as compared to the main droplet, thought to be subjected to more backward forces by surface tension at the time the small dot is pulled away from the meniscus of the ink ejection bore, and an ejection speed of the small droplet is slower than that of the main droplet. Since the main droplet ejected from a large-droplet nozzle array for ejecting relatively large ink droplets has a large dot diameter, the satellite having a slow ejection speed is landed to overlap over the main droplet on a sheet at the time it is landed thereon. On the other hand, since the main droplet ejected from a small-droplet nozzle array for ejecting relatively small ink droplets has a relatively small dot diameter, the satellite having a slow ejection speed is landed away from the main droplet on a sheet at the time it is landed thereon. In this way, since the satellites form dots which are not intended originally, many proposals have been made as technologies for restricting the satellite (for example, refer to Japanese Patent Laid-Open No. 2007-118300), but it is difficult to restrict occurrence of the satellite.
In a printer using the printing head provided with large-droplet nozzle arrays for ejecting relatively large ink droplets and small-droplet nozzle arrays for ejecting relatively small ink droplets, the satellite of the small-droplet nozzle array is landed away from the main droplet as described above. Since the satellite generated in such a printing head has relatively low kinetic energy, a landing position of the satellite to the main ink droplet is disturbed by the self-current generated by ejection of the ink droplet and the flowing current generated by transfer of a carriage. The disturbance in the landing position of the satellite generates density variations to cause image quality to be degraded.
An object of the present invention is to provide a printing apparatus and a printing method capable of suppressing degradation of image quality due to disturbance in landing positions of satellites.
In a first aspect of the present invention, there is provided a printing apparatus includes a scanning mechanism adapted to scan a print medium with a printing head in a scan direction, the printing head having a first nozzle array ejecting relatively large ejection amount of ink, a second nozzle array arranged on one side of the first nozzle array in the scan direction, and a third nozzle array arranged on the other side of the first nozzle array in the scan direction, the second and third nozzle arrays ejecting a relatively small ejection amount of ink with the same color, respectively, and a controller adapted to control a printing rate of one of the second and third nozzle arrays located at the front side in the scan direction lower than that of the other located at the back side.
In a second aspect of the present invention, there is provided a printing method printing method having a step of scanning a print medium with a printing head, the printing head having a first nozzle array adapted to eject relatively large ejection amount of ink, a second nozzle array arranged on one side of the first nozzle array in a scan direction, and a third nozzle array arranged on the other side of the first nozzle array in the scan direction, the second and third nozzle arrays adapted to eject a relatively small ejection amount of ink with the same color, respectively, and a step of controlling a printing rate of one of the second and third nozzle arrays located at the front side in the scan direction lower than that of the other located at the back side.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Hereinafter, an embodiment of the present invention will be described below in detail with reference to the attached drawings. However, components described in the embodiment are shown only as an example and the scope of the present invention is not limited thereto only.
The platen 5003 is disposed a printing position facing to an ink ejection port formation surface (an ejection surface) of the inkjet-type printing head 5004 to support a reverse side of a print medium P and maintain a constant distance between an obverse side of a print medium P and the ejection surface. After a print medium P is conveyed on the platen and printed an image thereon, the print medium P is nipped between a discharging roller 5005, which is rotating, and a spur 5006 as a rotor, which follows the discharging roller 5005, thereby the print medium P is conveyed in the direction of A and discharged from the platen 5003 to a discharge tray 1004. The discharging roller 5005 and the spur 5006 are constituent of a second conveying means downstream in the conveying direction of the print medium P.
The printing head 5004 is removably mounted on a carriage 5008 so that the ejection surface of the printing head 5004 faces to the platen 5003 or a print medium P thereon. The carriage 5008 is moved back and forth along two guide rails 5009 and 5010 by driving force of a carriage motor. And the printing head 5004 performs an ink ejection operation in accordance with printing data in the back and forth movement.
In the print element unit H1002, formation of a plate joint body (element substrate) by the jointing of the first plate and the second plate, mount of the print element to the plate joint body, lamination of the electrical wiring tape and electrical joint between the tape and the print element, sealing of the electrical connection portion and the like are carried out in that order. The first plate H1200 in which planarity is required in view of an influence on an ejection direction of the droplet is configured by, for example, an alumina (Al2O3) material having a thickness of 0.5 to 10 mm. In the first plate H1200, an ink supply port H1202 for supplying ink of black to the first print element H1100 and ink supply ports H1201 for supplying ink of cyan, magenta, yellow, and black are formed.
The second plate H1400 is a single sheet-shaped member having a thickness of about 0.5 to 1 mm and has window-shaped ports H1401 each larger than a contour dimension of each of the first print element H1100 and the second print element H1101 bonded and fixed to the first plate H1200. The second plate H1400 is laminated and fixed with an adhesive agent on the first plate H1200 to form the plate joint body.
The first print element H1100 and the second print element H1101 are bonded and fixed to a surface of the first plate formed in the ports H1401. It is difficult to accurately mount the print element on the first plate due to low positioning accuracy when bonding and fixing the first print element H1100 and the second print element H1101 to the first plate and displacement of the adhesive agent. An assembly error of the printing head can cause a landing deviation of ink to be described below.
Each of the print elements H1100 and H1101 having the print element arrays H1104 is formed of a well known structure as a side shooter bubble jet (registered trademark) substrate. The print elements H1100 and H1101 have ink supply ports, heater arrays and electrode portions. A TAB tape is adopted in the electrical wiring tape (hereinafter, wiring tape) H1300. The TAB tape is formed of a tape substrate (base film), a copper foil wire and a laminated body of a cover layer.
Inner leads H1302 as connection terminals extend in two sections of a device hole corresponding to the electrode portion of the print element. The wiring tape H1300 is bonded and fixed at a side of the cover layer to a surface (tape bonding surface) of the second plate through a thermosetting epoxy plastic bonding layer and the base film of the wiring tape H1300 serves as a smooth capping surface which a capping member of the print element unit is in contact with.
Next, a printing method according to the first embodiment in the present invention will be explained. It should be noted that in the present embodiment, there is explained an example of a two-path print where a print of an image to a unit region of the print medium is completed by one back and forth scan to the unit region, that is, two scans to the unit region. In the present embodiment, there is explained a case of using the nozzle arrays YL1 and YL2 and the nozzle arrays MS1 and MS2.
In the printing method of the present embodiment, a ratio between a printing rate of the nozzle array MS1 and a printing rate of the nozzle array MS2 is changed corresponding to a scan direction of the printing head. Specifically among the nozzle arrays MS1 and MS2, the printing rate of the nozzle array located at the front side in each scan direction is set smaller than the printing rate of the nozzle array located at the backward side. Herein, the printing rate is defined as a rate of pixels being allowable to be output (printed) with respect to all pixels in a unit area. In a general method for altering the printing rate, a mask pattern defining whether to allow an ejection of an ink droplet to each pixel is applied to binary printing data defining whether to eject an ink droplet to each pixel. The printing method of the present embodiment is a so-called bi-directional multi-path printing method in which a print to a unit region on a print medium is completed by at least one back and forth scan to the unit area. In this multi-path printing method, a rate (ratio) of print data of which output (print) is permitted for each scan is in advance determined by a mask.
Here, an operation of the printing method in the present embodiment will be explained. As shown in
Therefore, in the present embodiment, a printing rate of the nozzle array located at the front side in each scan direction of the nozzle arrays MS1 and MS2 is set to be lower than a printing rate of the nozzle array located at the backward side, thereby suppressing the landing deviation of the satellite. That is, in the present embodiment, to the first nozzle array ejecting ink of a relatively large ejection amount, the printing rates of the second nozzle array and the third nozzle array which are arranged respectively to the forward side and the backward side in the scan direction of the first nozzle array and which eject ink of a relatively small ejection amount are set as described above. It should be noted that herein, each of the second nozzle array and the third nozzle array may be the nozzle array ejecting ink of the same color, and the first nozzle array may be the nozzle array ejecting ink of the same color as or of a color different from the color of the second nozzle array and the third nozzle.
As described above, in the arrangement where a plurality of nozzle arrays including the first to third nozzle arrays are arranged along the scan direction, two or more of the first nozzle arrays are sequentially arranged in the scan direction, and the second and third nozzle arrays respectively are arranged adjacent to the first nozzle array at both sides of the first nozzle array, the printing method of the present embodiment is particularly suitable. This is because in such a configuration, the air flow from the two sequential nozzle arrays each having large ink droplets is very influential and the landing deviation in the satellite of each of the second and third nozzle arrays can be suppressed by setting the printing rates of the second and third nozzle arrays as described above.
Table 1 shows an example of printing rates in each scan direction in the present embodiment. In this example, in the forth scan, the printing rate of the nozzle array MS1 is set as 0%, and the printing rate of the nozzle array MS2 is set as 50%, and in the back scan, the printing rate of the nozzle array MS1 is set as 50%, and the printing rate of the nozzle array MS2 is set as 0%.
Table 2 shows an example as a comparative example in a case where the printing rates of the nozzle arrays MS1 and MS2 are equally distributed for a print.
It should be noted that in the example in Table 1, one of the printing rates of the nozzle arrays MS1 and MS2 is set as 0% and the other is set as 50%, but for example, as shown in Table 3, the one may be set as 37.5% and the other may be set as 12.5%.
Table 4 shows another example of printing rates in each scan direction in the present embodiment. The example in Table 4 adopts the nozzle arrays YL1 and YL2, the nozzle arrays MS1 and MS2, and the nozzle arrays CS1 and CS2. As shown in Table 4, one of the printing rates in the nozzle arrays of magenta close to yellow is set as 35% and the other is set as 15%. Further, since cyan distant from yellow is difficult to be influenced by air flow due to ejection of the yellow, both of the printing rates in the nozzle arrays of the cyan can be respectively set as 25%.
Here, in the present embodiment, a printing method when setting a printing rate of each of the nozzle arrays as described above will be explained.
Each of the nozzle arrays MS1, YL1, YL2 and MS2 having 128 nozzles is divided into 8 blocks respectively having 16 nozzles in the sub-scan direction. One type of mask pattern is given to one block of the 8 blocks for every print by one scan. Alphabets A to D in
Referring again to
The masks C and D are applied to the nozzle arrays MS1, MS2. In particular, to the nozzle array MS1, the mask C is used in the first path, and the mask D is used in the second path. The mask C has no permissive printing pixel, so all of printing data given to the nozzle array MS1 is printed in the second path using the mask D. On the other hand, to the nozzle array MS2, the mask D is used in the first path, and the mask C is used in the second path. Accordingly, all of printing data given to the nozzle array MS2 is used in the first path. As a result, it can be possible to lower the printing rate of the nozzle array MS1 and to increase the printing rate of the nozzle array MS2 in the forth scan, and to increase the printing rate of the nozzle array MS1 and to increase the printing rate of the nozzle array MS2 in the back scan, as shown in Table 1.
In addition, when printing the unit regions I and III, the masks used for the unit region II are used for the first and second paths in reversal order. As described above, printing to each of the unit regions I to III can be performed by printing with the masks A to D, which are assigned to the respective nozzle arrays, as shown in
In a case where the printing rates of Table 3 are used, masks E and F shown in
Next, a printing method according to a second embodiment in the present invention will be explained. It should be noted that in the present embodiment, there will be explained an example of a two-path print where a print of an image to a unit region on a print medium is completed by one back and forth scan, that is, two scans to the unit region. In the present embodiment, there will be explained a case where in addition to the nozzle arrays YL1 and YL2 and the nozzle arrays MS1 and MS2, the nozzle arrays ML1 (fourth nozzle array) and ML2 (fifth nozzle array) are used.
In the printing method, the printing rates in the nozzle arrays ML1 and MS1 and the printing rates in the nozzle arrays ML2 and MS2 change depending on a scan direction of the printing head. In particular, the printing rate in the nozzle array MS1 (or MS2) located at the forward position in each scan direction is set to be smaller than the printing rate in the nozzle arrays MS2 (or MS1) located at the backward position. In addition to it, the printing rate in the nozzle array ML1 (or ML2) located at the forward position in each scan direction is set to be higher than the printing rate in the large-droplet nozzle array of the nozzle array ML2 (or ML1) located at the backward position.
The reason for increasing the printing rate of the nozzle array ML1 (or ML2) as the large-droplet nozzle array located at the forward side in each scan direction is to suppress an influence of air flow on the nozzle array MS1 (MS2) located at the backward side thereof. That is, the printing rate of the nozzle array ML1 is 50% in the forth scan, but the nozzle array MS1 is difficult to be influenced by the air flow of the nozzle array ML1 since the nozzle MS1 is located at the back side of the nozzle array ML1 in the scan direction, to restrict the landing deviation of the satellite in the nozzle array MS1. The printing rate of the nozzle array ML2 is 0%, but the nozzle array MS2 is easy to be influenced by the air flow of the nozzle array ML2 since the nozzle MS2 is located at the forward side of the nozzle array ML2 in the scan direction, to suppress the landing deviation of the satellite in the nozzle array MS2. In the back scan also, the landing deviation of the satellite of each of the nozzle arrays MS1 and MS2 can be likewise suppressed.
It should be noted that if each of the fourth nozzle array and the fifth nozzle array is larger in an ejection amount that each of the second nozzle array and the third nozzle array, a magnitude relation of the ejection amounts thereof with the ejection amount of the first nozzle array is not limited to the above relation. For example, each ejection amount of the fourth and fifth nozzle arrays may be larger than each ejection amount of the second nozzle array and the third nozzle array and may be smaller than that of the first nozzle array.
In this way, the present embodiment is applied to a case where the fourth nozzle array located at an opposing side of the first nozzle array to the second nozzle array in a scan direction and the fifth nozzle array located at an opposing side of the first nozzle array to the third nozzle array in a scan direction are used for a print. In addition, in the printing head where the second nozzle array and the fourth nozzle array are positioned adjacent to each other and the third and fifth nozzle arrays are positioned adjacent to each other, the influence of the air flow from the fourth and fifth nozzle arrays to the second nozzle array and the third nozzle array is large, and the above printing method is particularly effective.
Table 5 and Table 6 show examples in each scan direction in the present embodiment.
Table 7 shows another example in each scan direction in the present embodiment. Table 7 shows a case of using all the nozzle arrays.
It should be noted that a definition of the printing rate in each path of each embodiment may be made as software of the CPU, and may be provided by appropriate hardware, for example, as a part of a circuit arrangement of an ASIC.
In the above-mentioned embodiment, among the multi-path printing methods where the printing head performs plural times of scans in a unit region for printing, the multi-path print of two paths is explained. However, the present invention is not limited thereto, and a one-path print or a more-path print may be applicable. The above embodiment shows an example where in the bi-directional printing method, the printing rate of each of the second nozzle array and the third nozzle array (or fourth nozzle array and fifth nozzle array) is reversed depending on the scan direction, but in a one-way printing method, the printing rate of each of the second to fourth nozzle arrays may be fixed.
Further, the landing deviation of the satellite can be reduced by making the printing rates of the second nozzle array and the third nozzle array differ, but the effect of printing one raster with different nozzles is reduced. Therefore, when the influence of the air flow of the first nozzle array ejecting large ink droplets is large, that is, when the print rate of the first nozzle array is high, the printing rates of the second nozzle array and the third nozzle array may be made different. For example, in a print mode where the multi-path number (number of times of scans for completing a print in a unit region) is relatively small, the printing rates of the second nozzle array and the third nozzle array may be made different, and in a print mode where the multi-path number is relatively large, the printing rates of the second nozzle array and the third nozzle array may be made equal. In addition, also when performing a print at the same path number, it is determined whether the print duty of the first nozzle array is more than or less than a predetermined value, and the printing rates of the second nozzle array and the third nozzle array may be made different depending on the determination result. In this arrangement, the CPU 201 analyzes the print data to determine the print rate of each of the nozzle arrays YL1 and YL2 for setting the printing rate of each of the second nozzle array and the third nozzle array, but the print duty may be determined based upon any of the multi-valued print data and the binary print data.
Further, in the embodiment described above, an explanation was made in the case where a two-path print is employed as a multi-path print and a printing rate of 50% is given to each pat. However, a total of printing rates given to respective scans in a multi-path print may be greater than or smaller than 100%.
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. 2009-186575, filed Aug. 11, 2009, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2009-186575 | Aug 2009 | JP | national |
