Patent Grant
8262191
1. Field of the Invention
The present invention relates to a printing apparatus and a printing method in which a print medium is printed by allowing a print head to eject ink, and in particular, to a printing apparatus and a printing method which involve sensing of the condition in which ink is ejected through ejection ports.
2. Description of the Related Art
In recent years, ink jet printing apparatuses have been prevailing rapidly, wherein printing is performed by allowing a print head to eject ink droplets onto a print medium. Many ink jet printing apparatus adopt an ink droplet ejection method in which ink is heated to cause film boiling so that the resulting pressure allows ink droplets to fly as an ink droplets ejection method. Unlike an electrophotographic scheme, this method requires no intermediate transfer unit and thus needs few intervening elements in forming images. Hence, the method has the advantage of allowing intended images to be stably obtained.
On the other hand, in the ink jet printing apparatus, inappropriate ink ejections may result from, for example, blockage of ejection ports by dust or thickened ink or coverage of ejection ports with ink droplets. Such an inappropriate ink ejection may be an ejection failure state in which no ink droplets are ejected from ejection ports, a state in which ink droplets are ejected but in which an ejection speed is lower than a predetermined value, resulting in a failure to impact print media, or deviation of impact positions of ejected ink droplets. When such an inappropriate ink ejection is occurred, particularly in an ink jet printing apparatus with a small number of passes, corresponding defective portions concentrate in particular areas of print images. Thus, there are some cases that white or black stripes are generated.
The ink jet printing apparatus with a small number of passes is used by the printing apparatus to perform printing relatively large-sized print media mainly, for example, used for commercial applications such as printing of posters and POP advertisements and industrial applications. Thus, to prevent the above-described image defects (white or black stripes), some printing apparatuses configured to print relatively large-sized print media perform what is called ejection failure compensation printing in which an ejection port located adjacent to an ejection port with an inappropriate ejections is used to carry out compensation printing. Therefore, even when the ejection failure state is detected, forming of high quality image printing is kept.
A technique using a light emission element and a light reception element is known as means for sensing the occurrence position of the ink ejection failure state for the ejection failure compensation printing. In a method for sensing the ink ejection failure state using this sensing means, the light emission element and the light reception element are positioned such that ink droplets pass between these elements. Thus, when ink is ejected, a change in the quantity of light passing between these elements is sensed. In this manner, the occurrence position of the ejection failure state is sensed by sequentially detecting, for each ejection port, whether or not light emitted by the light emission element is blocked by ink droplets.
In the sensing of the ejection failure state, the ejection failure state can be found earlier by increasing the frequency of sensing operations. Then, ejection ports in the ejection failure state can be compensated for. However, since the process of sensing is carried out individually on the respective ejection ports, particularly if the printing apparatus includes a large number of ejection ports like those configured to print large-sized print media as described above, printing needs to be halted for a long time. Thus, when the sensing of the ejection failure state is excessively frequently carried out, the time for which printing is suspended for the sensing of the ejection failure state increases unnecessarily. This may reduce printing throughput.
In view of the above-described circumstances, in order to carry out a process of sensing the ejection failure state at a frequency such that a decrease in throughput is minimized, while maintaining as high image quality as possible, Japanese Patent Laid-Open No. 2007-290352 discloses a method of adjusting the frequency of the ejection failure state sensing process with the accumulated number of ejections focused on. In Japanese Patent Laid-Open No. 2007-290352, the number of ink ejections is counted from the last ejection failure state sensing process. Then, when the ejection number exceeds a predetermined value, the next ejection failure state sensing process is carried out.
By the way, in recent years, even for printing apparatuses configured to print large-sized print media, there has been a demand for high-definition images of a photographic image quality level. For consumer use, ink jet printing apparatuses that use very small droplets have already been provided as instruments that print images with photographic image quality. Such ink jet printing apparatuses configured to print images with the photographic image quality generally eject at most 5 pl of droplets. The amount of the smallest droplets ejected in some recent ink jet printing apparatuses with such a configuration is smaller than 1 pl. The printing apparatus configured to eject very small droplets also includes ejection nozzles allowing formation of dots each corresponding to several dots of the smallest droplets to compensate lowered speed of printing generated by decrease in amount of droplets. Hence, recent ink jet printing apparatuses with the photographic image quality each include a plurality of ejection ports configured to eject different amounts of droplets in which both amounts are equal to or smaller than 5 pl.
The present inventors developed a printing apparatus configured to print large-sized print media and including a plurality of ejection ports configured to eject different amounts of droplets in which both amounts are equal to or smaller than 5 pl. However, the present inventors found that an ejection failure state not observed in the conventional art occurred in this printing apparatus. Furthermore, this new ejection failure state occurred much more frequently than those recognized in the conventional art. Thus, when an attempt is made to compensate for the ejection failure state with the conventional design concept unchanged, achieving both high image quality and a high throughput is very difficult.
Thus, in view of the above-described circumstances, an object of the present invention is to provide a printing apparatus and a printing method in which when an ink jet printing apparatus configured to perform ejection failure compensation printing is used for high-definition printing, the present invention allows, based on a new concept, a decrease in printing throughput to be suppressed while enabling the ejection failure state to be inhibited from occurring in ejection ports in a print head.
According to a first aspect of the present invention, there is provided a printing apparatus configured such that a print head comprising at least two ejection ports through which different amounts of ink in the same color is ejected, both ejection amounts being equal to or smaller than 5 pl, is mounted, the print head ejecting ink for printing through the ejection ports, wherein the printing apparatus comprises: an ejection failure state sensing unit for carrying out a first ejection failure state sensing process for sensing an ejection state of ink ejected through first ejection ports which have the smallest opening area in the ejection ports formed in the print head and for carrying out a second ejection failure state sensing process for sensing an ejection state of ink ejected through all the ejection ports in the print head, the second ejection failure state sensing process is carried out less frequently than the first ejection failure state sensing process, and wherein when any ejection port is determined to be in an inappropriate ejection state by the first ejection state sensing process or the second ejection state sensing process, compensation printing is carried out so as to compensate for a dot to be formed by the ejection port in the inappropriate ejection state using a different ejection port for printing with compensation.
According to a second aspect of the present invention, there is provided a printing method of performing printing using a printing apparatus configured to perform printing by allowing a print head including at least two ejection ports to eject different amounts of ink in the same color through the ejection ports, both ejection amounts being equal to or smaller than 5 pl, wherein the printing method comprises: a first ejection failure state sensing step of sensing an ejection state of ink ejected through first ejection ports which have the smallest opening area in the ejection ports formed in the print head; and a second ejection failure state sensing step of sensing an ejection state of ink ejected through all the ejection ports in the print head, the second ejection failure state sensing step is carried out less frequently than the first ejection failure state sensing step, and wherein when any ejection port is determined to be in an inappropriate ejection state by the first ejection state sensing step or the second ejection state sensing step, compensation printing step is carried out so as to compensate for a dot to be formed by the ejection port in the inappropriate ejection state using a different ejection port.
According to the present invention, if different frequencies of the ejection failure state result from printing with the use of a print head including at least two ejection ports through which different amounts of ink in the same color are ejected and in which both ejection amounts are small, the process of sensing the ejection failure state can be carried out in accordance with the likelihood of occurrence of the ejection failure state. Thus, the present invention minimizes the time for which printing is suspended by the ejection failure state sensing process with detecting the ejection failure state reliably, in accordance with the likelihood of occurrence of the ejection failure state. This allows a decrease in throughput to be minimized. The present invention can thus provide a printing apparatus and a printing method in which high-speed printing can be carried out with the quality of print images kept high.
Further features of the present invention will become apparent from the following description of exemplary embodiments (with reference to the attached drawings).
Embodiments for carrying out the present invention will be described below with reference to the drawings.
An ink jet printing apparatus according to a first embodiment of the present invention will be described. The ink jet printing apparatus according to the present embodiment is assumed to be used to print relatively large-sized print media, for example, used for commercial applications such as printing of posters and POP advertisements and industrial applications. Thus, an ink jet printing apparatus configured to print roll paper will be described.
As shown in
As shown in
If the roll paper cassette 89 is used to continuously print on roll paper, such a process as shown in
As shown in
As shown in
In the ejection port row through which each of the black ink and the yellow ink is ejected, 256 ejection ports 15, 18 are arranged at an arrangement density such that about 245 ejection ports 15, 18 are arranged per 1 cm. The ejection port row through which each of the black ink and the yellow ink is ejected is formed of the ejection ports 15 or 18 through which 5 pl of ink is ejected.
Furthermore, in the ejection port row through which each of the cyan ink and the magenta ink is ejected, 512 ejection ports 16, 17 are arranged at an arrangement density such that about 490 ejection ports 16, 17 are arranged per 1 cm. The ejection ports 16 through which the cyan ink is ejected include a row formed of ejection ports 16a through which 5 pl of ink is ejected and a row formed of ejection ports 16b through which 1 pl of ink is ejected. The ejection ports 17 through which the magenta ink is ejected include a row formed of ejection ports 17a through which 5 pl of ink is ejected and a row formed of ejection ports 17b through which 1 pl of ink is ejected. That is, of a total of 1,024 cyan ejection ports, 512 ejection ports each include 1-pl nozzle. Of a total of 1,024 magenta ejection ports, 512 ejection ports each include 1-pl nozzle. As described above, the plurality of ejection ports 19 in the print head 111 include ejection ports with a relatively small opening area and an ejection amount of 1 pl (first ejection ports) and ejection ports having a larger opening area than the first ejection ports and having an ejection amount of 5 pl (second ejection ports). Thus, the printing apparatus according to the present embodiment is configured as described above, thus enabling printing of photographic quality, for example, printing of photographs and posters. The reason why no ejection port with an ejection amount of 1 pl is formed in the ejection port rows through which yellow ink and black ink are ejected is as follows.
For yellow, the difference in ejection amount is difficult to perceive by human beings. Black is infrequently used for tonal expression.
Of course, if the relationship with the printing speed is not very important, ejection ports with an ejection amount of 1 pl may be provided for these ink colors.
In two-way printing in which the print head 111 carries out printing in both a forward scanning direction and a backward scanning direction, the color impression may vary depending on the moving direction of the carriage owing to the order of impacts and the adverse effect of air flows. Thus, the print head 111 is difficult to use for two-way printing and is thus often used for one-way printing. However, the present invention is not limited to applications to one-way printing but may be applied to printing apparatuses configured to carry out two-way printing.
Four print heads 11 to 14 configured to eject ink in the respective colors are supplied with ink in the corresponding colors through supply ports 23. The supply ports 23 are coupled to respective plural ink tanks in which different types of ink (black, yellow, magenta, and cyan) are accommodated. To compensate for consumption of ink, the supply ports 23 allow new ink to be uninterruptedly supplied to ejection ports 19 through which the ink has been ejected or sucked.
Now, an ejection failure compensation method according to the present embodiment will be described.
First, the configuration of an ejection failure state sensing unit configured to carry out the ejection failure state sensing process will be described.
When the ejection failure state sensing unit 112 configured as described above carries out the ejection failure state sensing process, the ejection failure state sensing process for the plurality of ejection ports 19 present on an optical axis can be accomplished through one alignment operation. Thus, in a print head in which ejection ports are arranged in a plurality of rows, provided that the positional relationship is adjusted such that the each ejection port row is placed on the optical axis, the sensing process can be carried out on all the ejection ports by moving the print head a number of times corresponding to the number of rows.
Ejection failure compensation printing is carried out for ejection ports determined by the above-described ejection failure state sensing process to be in the ejection failure state. The reason is as follows. If any ejection port is in the ejection failure state, the corresponding pixel on printed matter is missing. Thus, when printing is continued with no appropriate measures taken, the resulting image may be blurred or the characters may be difficult to read. Here, the ejection failure state refers to the state in which no ink droplet is ejected though the ejection ports during printing for any reason. In the present embodiment, the ejection failure sensing means senses the state in which no ink droplet is ejected though the ejection ports. However, the ejection failure sensing means may sense any other inappropriate ink ejection state. Such an inappropriate ink ejection state may be, for example, deviation of impact positions resulting from an insufficient ejection speed or blurred printing resulting from insufficient refilling.
Any of the following three methods may be used for the ejection failure compensation printing, that is, a printing method for compensating for the ejection port in the ejection failure state, through which no ink droplets are ejected.
In a first method (adjacent ejection-port compensation), if any ejection port is in the ejection failure state, the dot to be ejected through the ejection port is distributed to ejection ports located at the both of the adjacent ejection ports in the ejection failure state. In another method (different-color compensation), if any cyan ejection port is in the ejection failure state, for example, an ink dot in another color is used to compensate for the data corresponding to the cyan ejection port in the ejection failure state. In yet another method, in a divisive printing scheme in which printing is performed by allowing the print head to carry out a plurality of scans, a portion in the ejection failure state is compensated for by other normal ejection ports. The present invention may adopt any of the ejection failure compensation schemes. The present embodiment will be described mainly in conjunction with an example of adjacent ejection-port compensation. However, ejection failure compensation printing used for the present invention may include not only an ejection failure compensation scheme described above but also ejection failure compensation printing based on a scheme other than those described above.
Now, a specific method for the ejection failure state sensing process, an essential part of the present invention, will be described.
Firstly, a detailed description will be given of an ejection failure phenomenon that occurred in a printing apparatus configured to print large-sized print media and to offer photographic image quality, that is, including a plurality of ejection ports through which different amounts of ink are ejected and in which the different amounts are equal to or smaller than 5 pl.
The ejection failure phenomenon exhibited two characteristics.
First, the frequency of occurrence of the ejection failure phenomenon is one digit higher than that conventionally recognized.
Second, the phenomenon has failed to occur in conventional, similarly configured printing apparatuses for consumer use.
In particular, adverse effects related to the frequency are critical. If the ejection failure sensing process is carried out in accordance with the frequency as in the conventional art, printing needs to be halted for a significantly long time in total. Furthermore, for faster printing, the ink jet printing apparatus configured to print large print media and including differently sized ejection ports has a much larger number of ejection ports than in the conventional art. Thus, the ejection failure sensing process results in the need for a longer printing halt time than in the conventional art.
Thus, there has been a demand for a new method and a new printing apparatus which enable ejection failure compensation printing in spite of the above-described frequently-occurring ejection failure state, without affecting an expected high-speed printing capability.
The present inventors further studied the frequently-occurring ejection failure state. Then, the present inventors found that the ejection failure state occurs only in the smaller ones of the plurality of ejection ports through which the different amounts of ink are ejected and in which both the ejection amounts are equal to or smaller than 5 pl.
This discovery has led the present inventors to the present invention for the first time.
Because, in the conventional art, for some time after the printer has started to be used, the ejection failure state occurs very infrequently. Moreover, there is not so great a difference in occurrence frequency between the large and small ejection ports both of which have an ejection amount of equal to or more than 5 pl. Thus, the ejection failure state sensing process is normally carried out evenly on all the ejection ports in the print head at given intervals in the conventional printing apparatus.
Hence, in the above-described environment, the ejection failure sensing process inevitably requires a significantly long time, thus enhancing the tradeoff relationship between the throughput and the maintenance of image quality.
However, the present inventors have found for the first time that the occurrence frequency of the ejection failure state in particular ejection ports is extremely different from that in the other ejection ports. Thus, the present inventors have successfully reduced the time required for the frequently executed ejection port sensing process by making the frequency of the ejection failure sensing process executed on the particular ejection ports different from that of the ejection failure sensing process executed on the other ejection ports.
Thus, the tradeoff relationship between the throughput and the maintenance of image quality has been corrected.
When it is considered that the above-described conventionally-unexpected ejection failure state occurred only in the small ejection ports and did not occur in conventional consumer use, it is predicted that the new ejection failure state is caused by a combination of the following factors.
That is, the factors causing the ejection failure state include structural factors and use environment factors.
One of the structural factors is a decrease in a margin for the maintenance of ejection characteristics caused by an increase in resistance of ink moving forward associated with very small ejection ports.
The use environment factors as the other structural factor is structure of the likelihood that the ejection ports are likely to become hotter than in the conventional art and the environment in which the ejection ports are used at high temperature (this environment is hereinafter simply referred to as the high-temperature environment).
First, the decrease in the margin for the maintenance of the ejection characteristics caused by the increase in resistance of ink moving forward will be described. The flow resistance in the front of the bubbling chamber increases with decreasing ejection port opening area as the square of the opening area. Thus, for small-diameter ejection ports with high resistance of ink moving forward, bubbling power is set to be higher than in the conventional art to keep the ejection state in balance. On the other hand, the increased bubbling power escapes toward the rear of the bubbling chamber, which offers relatively low flow resistance. This is expected to significantly reduce the margin for maintaining the appropriate ejection state. This tendency is observed in structures with an ejection amount of about equal to or larger than 2 pl. Thus, when the environment in the bubbling chamber changes, for example, bubbles are generated in the bubbling chamber, the bubbling power is prevented from being sufficiently transmitted to the ejection port side. As a result, possibility that droplets are prevented from being ejected is generated potentially.
Now, the high-temperature environment will be described.
In general, when the temperature of the print head increases, bubbles may be likely to be generated in the bubbling chamber. This is because gas dissolved in the ink is segregated in a high-temperature environment. The segregated dissolved gas is normally discharged during ejection or quickly re-dissolved into the ink while printing is halted. Thus, the gas poses no problem.
However, in printing of large print media, for example, printing of posters for industrial applications, when the printing operation is halted before one print medium is completely printed, the ejection state changes slightly in the corresponding portion of the print medium. Furthermore, the color impression changes in that portion of the print medium. Thus, it is not preferable to halt the printing operation before at least one print medium is completely printed. Then, continuous printing time increases inevitably depending on the size of the print media. Thus, the heaters are continuously driven for a long time in order to allow in droplets to be consecutively ejected. Hence, the temperature of the print head is likely to increase. This also increases the time intervals at which a recovery process such as preliminary ejection is carried out for every predetermined number of print media.
Moreover, if the printing apparatus is used for an industrial application, the printing speed is emphasized. Thus, the interval between the end of printing of one print medium and the start of printing of the next print medium is frequently set to be relatively short. Even when bubbles are generated inside the bubbling chamber, if a long interval is provided between the end of printing of one print medium and the start of printing of the next print medium, the bubbles often contract and disappear during the interval. However, in the industrial printing apparatus, the bubbles may be prevented from contracting and disappearing between the end of printing of one print medium and the start of printing of the next print medium. As a result, the bubbles may remain inside the bubbling chamber.
Furthermore, where the ejection ports are arranged at a high integration density, heat is difficult to diffuse or radiate. Additionally, when the entire surface of the print medium is continuously printed with a small number of passes by the print head, ejection is consecutively carried out at high frequency. The heaters are consecutively driven. Thus, heat is difficult to radiate from the heaters and is prone to build up in the print head. Hence, the temperature of the print head as a whole is likely to increase. In particular, the temperature is more likely to increase around a central portion of the print head from which only a small quantity of heat is radiated.
This indicates that in the above-described high-temperature environment, bubbles are likely to be segregated in the bubbling chamber.
Therefore, it is expected that in the environment in which the ejection failure state is potentially likely to occur, the ejection failure state in this case occurred when the head was driven in a thermally harsh condition.
A specific ejection failure compensation method according to the present embodiment will be described.
In the present embodiment, while a printing operation is being performed, an ejection failure state sensing process is carried out on the ejection ports 15 formed in the print head at a predetermined timing. In the present embodiment, two types of ejection state sensing processes, a first ejection failure state sensing process 7B and a second ejection state sensing process 7A are carried out on the ejection ports 15. The first ejection failure state sensing process 7B of sensing only the small ejection ports 16b and 17b which are included in the ejection ports 19 on the print head and which have a relatively small opening area is carried out a plurality of times in parallel with an inter-page process. In the first ejection failure state sensing process 7B, the ejection failure state is sensed within 5 seconds. Furthermore, besides the first ejection failure state sensing process 7B, the second ejection failure state sensing process 7A is carried out on all the ejection ports 19 on the print head. The ejection failure state sensing process of sensing all the ejection ports 19 has been found to require about 15 seconds.
Here, the inter-page process refers to steps included in the inter-page process in
Adoption of these ejection state sensing processes allow the ejection failure compensation process to maintain high image quality while minimizing a decrease in throughput.
Now, with reference to
Compared to the comparative example (
The above-described ejection failure compensation printing is suitable for industrial applications in which relatively large-sized print media are printed as in the case of the printing apparatus according to the present embodiment. When the ejection failure compensation printing is performed, even if any ejection port is determined to be in the ejection failure state, the ink ejection from the ejection port in the ejection failure state can be compensated for without the need to suspend the printing. Thus, when large-sized print media are printed, even if any ejection port is determined to be in the ejection failure state during printing of one print medium, the printing can be continued without being suspended. If any ejection port is determined to be in the ejection failure state during printing of one print medium, when a recovery process is carried out on the ejection port, the printing is temporarily suspended in order to allow the recovery process to be carried out. If the printing is suspended in order to allow the recovery process or the like to be carried out on the ejection port in the ejection failure state, the color impression observed before the interruption may be different from those observed after the interruption. When the color impression is changed during printing of one print medium, the quality of the print image may be degraded. In contrast, in the printing apparatus according to the present embodiment, even if any ejection port is determined to be in the ejection failure state during printing of one print medium, a print area covered by the ejection port can be compensated for by the ejection failure compensation process. This eliminates the need to suspend the printing. Thus, the color impression can be prevented from being changed by the suspension of printing of one print medium. This enables the quality of print images obtained by the printing to be kept high. Thus, if relatively large-sized print media are printed, the ejection failure compensation printing is desirably carried out on ejection ports in the ejection failure state so as to prevent the quality of print images from being degraded.
The flow of control for the printing operation and ejection failure state sensing process according to the present embodiment will be described with reference to
The printing operation and ejection failure state sensing process according to the present embodiment are started (S201). Then, before the first page is printed, the second ejection failure state sensing process 7A is carried out on all the ejection ports to sense the ejection failure state (S301). Based on the sensing result, the process determines whether or not each of all the ejection ports is in the ejection failure state (S302). If any ejection port is in the ejection failure port, a flag is set (S303). If no ejection port is in the ejection failure state, the process shifts to the printing operation. Then, in the first printing operation, printing operation for one print medium is performed normally. At this time, if during the already carried-out ejection failure state sensing process 7A, any ejection port is found to be in the ejection failure state, then in addition to the normal printing operation, the ejection failure compensation printing is performed on the print medium (S213). Furthermore, if no ejection port is in the ejection failure state, the normal printing operation is performed (S203). When printing of one page is finished, the ejection failure state sensing process 7B is carried out concurrently with the inter-page processing as the first ejection failure state sensing process for only the small-diameter ejection ports (S204). In the present embodiment, every time printing of one page is finished, the ejection failure state sensing process 7B is carried out concurrently with the inter-page processing. The inter-page processing is between the step of feeding of roll paper and the step of returning of the roll paper shown in
If during the ejection failure state sensing process 7B, any ejection port is sensed to be in the ejection failure state (S205), a flag is set (S206). If during the ejection failure state sensing process 7B, no ejection port is sensed to be in the ejection failure state, the flag is not set and the flow progresses without any interruption. In S207, the process checks whether or not all the pages have been printed.
If not all the pages have been printed, then in S209, the process checks whether or not printing of (t) pages has just been finished. If the current timing is not the one when printing of (t) pages has just been finished, the flow returns to S202. If the current timing is the one when printing of (t) pages has just been finished, the ejection failure state sensing process 7A is carried out on all the ejection ports (S210). If during the ejection failure state sensing process 7A, any ejection port is sensed to be in the ejection failure state (S211), the flag is set (S212). If during the ejection failure state sensing process 7A, no ejection port is sensed to be in the ejection failure state, the flag is not set, and the flow progresses without any interruption.
Upon returning to S202, the process checks whether or not the flag has been set. If process determines that the flag has been set and thus that any ejection port is in the ejection failure state, then in addition to the normal printing operation for one print medium, the ejection failure compensation printing is performed (S213). When the normal printing operation and the ejection failure compensation printing are performed in S213, the flag is cleared. Thereafter, in S204, the ejection failure state sensing process 7B for the small-diameter ejection ports is carried out. Then, similarly, if during the ejection failure state sensing process 7B, any ejection port is sensed to be in the ejection failure state, then in S206, the flag is set, and the flow advances to S207. If no ejection port is sensed to be in the ejection failure state, the flow progresses without any interruption. Then, in S207, the process checks whether or not (n) pages of print media have been printed. The flow is repeatedly carried out on all of the (n) pages. When printing of (n) pages is finished, the printing operation and ejection failure state sensing process according to the present embodiment are completed (S208). As shown in
As described above, the sensing process is focused on the ejection ports which have the smallest diameter so as to prevent the image quality from being degraded by the ejection failure state of the ejection ports which have the smallest diameter in the plural types of the ejection ports. This is because the ejection failure state is relatively likely to occur at the ejection ports which have the smallest diameter in the plural types of the ejection ports. The present embodiment thus enables the ejection ports in which the ejection failure state is likely to occur to be frequently sensed whether or not the ejection ports is in the ejection failure state, reliably. At the same time, by using the minimum ejection failure state sensing process, the present embodiment enables the quality of print images to be kept high, while allowing a decrease in throughput to be suppressed.
Furthermore, the CPU 1000 allows the light emission element 81 to emit light during the ejection failure state sensing process for the ejection ports. For the ejection failure state sensing process 7B for the relatively-small-diameter ejection ports, the CPU 1000 allows the light emission element 81 to emit light only to the positions corresponding to the relatively-small-diameter ejection ports. For the ejection failure state sensing process 7A for all the ejection ports, the CPU 1000 allows the light emission element 81 to emit light to the positions corresponding to all the ejection ports. Then, the CPU 1000 senses the quantity of light reaching the light reception element 82 via an area through which ink droplets pass. At this time, the quantity of light received by the light reception element and the quantity of light received by the light reception element during normal ink ejections are compared with each other. For the comparison, the quantity of light received during normal ejections, which quantity is stored in the storage area such as the ROM 1010 or the RAM 1020, is read. Then, the quantity of light received which is detected during the ejection failure state sensing process and the quantity of light received during normal ejections are compared with each other. In this case, a voltage value obtained from the quantity of light received by the light reception element and a voltage value Vref as a reference obtained by the light reception element during normal ink ejections are compared with each other by using the comparator 83.
When any ejection port is sensed to be in the ejection failure state, the CPU 1000 allows, via the head driver 1030, the print head to perform the ejection failure compensation printing operation in addition to the normal printing operation. Thus, in the present embodiment, the CPU 1000 functions as first ejection failure state sensing unit for carrying out the first ejection failure state sensing process 7B of sensing the ejection state of the ink droplet ejected through which the relatively-small-diameter ejection ports. Furthermore, the CPU 1000 functions as second ejection failure state sensing unit for carrying out the second ejection failure state sensing process 7A of sensing the ejection state of the ink droplet ejected from all the ejection ports.
The following experiments were carried out to verify the effects of the present invention. In the experiments, first, one-way, 2-pass printing is performed using all of 5-pl ejection ports. A solid image is printed on 10 A4-sized sheets at a duty of 152%. Then, continuous 2-pass printing is performed using all of cyan and magenta 1-pl ejection ports. A solid image is printed on A4-sized sheets at a duty of 152%. The resulting images are then observed to check whether or not the ejection failure state is occurring. In these experiments, the printing conditions are the 2-pass printing, that is, relatively few passes printing. The printing conditions are a duty of 152%, that is, relatively high duty printing.
The first operation of printing a solid image on 10 sheets using the 5-pl ejection ports is to create an environment for continuous use. As printing is performed by such printing conditions, printing can be performed under printing condition being similar to continuous and severe printing condition performed by printing apparatuses for industrial applications or the like. Thus, in the 1-pl ejection ports, printing is performed under printing conditions in which the ejection failure state is more likely to occur than in the 5-pl ejection ports.
When the 5-pl ejection ports were used, no white stripes resulting from ejection failures were observed. In the experiments, in the printing apparatus according to the present embodiment, the ejection failure state was sensed for all the 1-pl ejection ports (a total of 512 nozzles) for each page. The ejection failure compensation printing was performed on an area corresponding to an ejection port determined to be in the ejection failure state. In contrast, in the comparative example, neither the sensing of the ejection failure state nor the ejection failure compensation printing was carried out.
About 10 verifications were carried out under the above-described conditions. In the comparative example, several white stripes seemingly resulting from ejection failures started to be observed on the fourth or fifth printed sheet. In contrast, in the embodiment, almost no white stripe was observed even on the 10th printed sheet. In the experiments, the time required to sense the ejection failure state for only the small-diameter ejection ports was 5 seconds for each page. The time required to sense the ejection failure state for all the ejection ports was 15 seconds for each page.
As a result, the ejection failure state was not observed in the ejection ports with an ejection amount of equal to or more than 5 pl. However, the results for the comparative example indicate that the ejection failure state occurs in the 1-pl ejection ports, leading to degradation of quality of print images. However, the printing apparatus according to the present embodiment frequently carries out sensing of the ejection failure state for the 1-pl ejection ports. Thus, if any ejection port is sensed to be in the ejection failure state, the ejection port in the ejection failure state can be recognized relatively early. Furthermore, even if the ejection failure state occurs in any ejection port, the ejection failure compensation printing is performed relatively early. Thus, the ejection port in the ejection failure state is compensated relatively early. Thus, in the printing apparatus according to the present embodiment, the quality of print images is prevented from being degraded as a result of the experiments.
Furthermore, sensing of the ejection failure state is frequently carried out on the small-opening-area ejection ports and the small ejection amount and is less frequently carried out on the ejection ports with the large opening area. In the present experiments, sensing of the ejection failure state was not carried out on the large-opening-area ejection ports. In this manner, sensing of the ejection failure state is carried out in accordance with the likelihood of occurrence of the ejection failure state. Hence, the processing can be accomplished with a prominent decrease in throughput prevented.
The first ejection failure state sensing process 7B need not necessarily be carried out while inter-page processing is being executed. For example, as disclosed in Japanese Patent No. 3382526, the first ejection failure state sensing process 7B may be carried out during the time between each scanning operations of the carriage while the print head 111 is not scanning.
Now, a second embodiment will be described with reference to
According to the above-described first embodiment, in the ejection ports in the print head 111 used in the printing apparatus, for each of the black ink and the yellow ink, one ejection port row is formed. For each of the cyan ink and the magenta ink, two ejection port rows are formed. Thus, the ejection port rows formed in the print head are not symmetric. Hence, while the print head 111 is scanning, the color impression may vary between the forward scanning direction and the backward scanning direction. Therefore, the print head 111 is not adapted for two-way printing. In contrast, a print head 111′ according to the second embodiment is different from the print head 111 according to the first embodiment in that in the second embodiment, the ejection port rows are symmetric.
Ejection port rows through which black ink, cyan ink, magenta ink, and yellow ink are ejected are formed in the print head 111′ in the ink jet printing apparatus according to the second embodiment. In the present embodiment, two black heads 14a and 14b configured to eject black ink are formed in a central portion of the print head. Yellow heads 13a and 13b configured to eject yellow ink are formed outside both the black heads 14a and 14b so as to sandwich both the black heads 14a and 14b between the yellow heads 13a and 13b. Furthermore, magenta heads 12a and 12b are formed outside the yellow heads 13a and 13b. Cyan heads 11a and 11b are formed outside the magenta heads 12a and 12b.
Ejection ports 15 through which black ink is ejected and ejection ports 18 through which yellow ink is ejected are all formed to have such a diameter as serves to provide an ink ejection amount of 5 pl. Furthermore, ejection ports 16 through which cyan ink is ejected include ejection ports 16a with such a diameter as serves to provide an ink ejection amount of 5 pl and ejection ports 16b with such a diameter as serves to provide an ink ejection amount of 1 pl. Ejection ports 17 through which magenta ink is ejected include ejection ports 17a with such a diameter as serves to provide an ink ejection amount of 5 pl and ejection ports 17b with such a diameter as serves to provide an ink ejection amount of 1 pl. In order to be symmetric, the print head 111′ according to the present embodiment includes an ejection port row formed inside and in which the ejection ports 16b, 17b with an ejection amount of 1 pl are arranged and an ejection port row formed outside and in which the ejection ports 16a, 17a with an ejection amount of 5 pl are arranged. Additionally, the two ejection port rows for each color are such that one of the ejection port rows is staggered with respect to the other ejection port row by half a pitch.
For the ejection ports 15 through which the black ink is ejected and the ejection ports 18 through which the yellow ink is ejected, 640 ejection ports are arranged at an arrangement density of about 245 nozzles per 1 cm. For the ejection ports 16 through which the cyan ink is ejected and the ejection ports 17 through which the magenta ink is ejected, 2,560 ejection ports are arranged at an arrangement density of about 980 nozzles per 1 cm. In the present embodiment, of the 5,120 cyan and magenta nozzles, 2,560 nozzles which is an ejection amount of 1 pl are formed.
As shown in
As described above, according to the present embodiment, if a print head with ejection port rows symmetrically arranged therein is adopted in order to increase the printing speed, the ejection failure state sensing process can be reliably accomplished without a decrease in printing throughput. Thus, even if the printing speed is increased to reduce the time required for printing, sensing of the ejection failure state is prevented from requiring an unnecessarily long time. This enables a reduction in printing time.
Now, an ink jet printing apparatus according to a third embodiment will be described. Components of the third embodiment which are configured similarly to the corresponding ones of the first or second embodiment are denoted by the same reference numerals and will not be described below. Only differences from the first and second embodiments will be described.
In the above-described first and second embodiments, when printing of each page is finished, the ejection failure state sensing process for the ejection ports is carried out concurrently with the inter-page processing. The time required for the ejection failure state sensing process for the ejection ports varies depending on conditions such as the number of ejection ports formed in the print head. The time required for the ejection failure state sensing process increases consistently with the number of ejection ports formed in the print head. If this amount of time exceeds the time required for the inter-page processing, the need to wait for the ejection failure state sensing process to be finished arises. Furthermore, this wait time tends to further increase consistently with the number of ejection ports, in order to deal with increased printing definition.
Thus, in order to further improve the throughput, the third embodiment caries out an ejection failure state sensing process 7B, that is, a first ejection failure state sensing process for each page, only on particular ones of the small-diameter ejection ports. In the present embodiment, particular ejection ports of the ejection ports of the small-diameter are the ejection ports through which the particular color ink is ejected. In the present embodiment, the first ejection failure state sensing process for each page is executed for the ejection ports of the small-diameter through which the particular color ink is ejected. For example, if the ejection failure state is likely to occur in ejection ports 16 through which cyan ink is ejected, then the first ejection failure state sensing process 7B is carried out, for each page, only on those of the cyan ejection ports 16b which have a small diameter. A third ejection failure state sensing process 7C is carried out on those of the ejection ports for the other ink colors which have a small diameter, at a frequency different from that for the first ejection failure state sensing process 7B and a second ejection failure state sensing process 7A. In the present embodiment, when the second ejection failure state sensing process 7A is carried out and 5 pages are printed, the third ejection failure state sensing process 7C executed.
As described above, in the third embodiment, when printing of each page is finished, the first ejection failure state sensing process 7B is carried out only on the ejection ports having a relatively small diameter and through which droplets in a color of which the ejection failure state is likely to occur are ejected. Then, when the printing for the predetermined sheets is finished, the second ejection failure state sensing process 7A is carried out on all the ejection ports at a frequency lower than that for the first ejection failure state sensing process 7B. Furthermore, the third ejection failure state sensing process 7C is carried out on the ejection ports having a relatively small diameter and on which the first ejection failure state sensing process has not been carried out, at a frequency different from those for the first and second ejection failure state sensing processes and at predetermined timings. Executing the ejection failure state sensing processes as described above enables a reduction in the wait time resulting from the first ejection failure state sensing process 7B while inhibiting the ejection failure state from occurring in the ejection ports.
Now, an ink jet printing apparatus according to a fourth embodiment will be described. Components of the fourth embodiment which are configured similarly to the corresponding ones of any of the first to third embodiments are denoted by the same reference numerals and will not be described below. Only differences from the first to third embodiments will be described.
In the third embodiment, the first ejection failure state sensing process is carried out on the particular small-diameter ejection ports, that is, the ejection ports having a relatively small diameter and through which ink in a particular color likely to be the ejection failure state is ejected. The third ejection failure state sensing process is carried out on the other relatively-small-diameter ejection ports. In contrast, in the fourth embodiment, a first ejection failure state sensing process 7B is carried out, for each page, on ejection ports having a small diameter and positioned in a particular area as a particular small diameter ejection ports. In the present embodiment, the particular area is the vicinity of the center of each ejection port row in which the ejection failure state is likely to occur. In the present embodiment, the first ejection failure state sensing process 7B is carried out at the ejection ports located in the vicinity of the center of each ejection port row, for each page. When a second ejection failure state sensing process 7A is carried out and 5 pages are printed, a third ejection failure state sensing process 7C is executed on the relatively-small-diameter ejection ports other than those on which the first ejection failure state sensing process 7B is selectively carried out. In the present embodiment, the first ejection failure state sensing process 7B is carried out, for each page, on 100 ejection ports having a small diameter and counted outward from the center of the ejection port row along the extending direction thereof. When the second ejection failure state sensing process 7A is carried out and 5 pages are printed, the third ejection failure state sensing process 7C is carried out on the other relatively-small-diameter ejection ports. The above-described particular color and the number of ejection ports counted from the center of the ejection port row are not limited to those described above and may be appropriately varied.
Now, an ink jet printing apparatus according to a fifth embodiment will be described. Components of the fifth embodiment which are configured similarly to the corresponding ones of any of the first to fourth embodiments are denoted by the same reference numerals and will not be described below. Only differences from the first to forth embodiments will be described.
The fifth embodiment is different from the first to forth embodiments in that the first ejection failure state sensing process 7B carried out on the small-diameter ejection ports is divided into a plurality of operations.
An increase in the number of small-diameter ejection ports correspondingly increases the time required for a first ejection failure state sensing process 7B. This in turn increases the time to wait for the first ejection failure state sensing process 7B to be finished, reducing the printing throughput. Thus, in the present embodiment, the first ejection failure state sensing process 7B is divided into a plurality of operations so that each of the operations can be finished within the time during which the inter-page processing is carried out.
In the present embodiment, the first ejection failure state sensing process 7B, carried out for each page, is executed only on some of the small-diameter ejection ports. The next first ejection failure state sensing process 7B is then carried out on the ejection ports on which the last first ejection failure state sensing process 7B has not been executed. In this manner, the ejection ports on which the ejection failure state sensing process is carried out in the first ejection failure state sensing process 7B are divided into groups. This reduces the number of ejection ports on which ejection failure state sensing process is carried out in a single first ejection failure state sensing process 7B. As a result, the time required for the ejection failure state sensing process 7B is shortened. In this case, if the time required for the ejection failure state sensing process 7B is shorter than the time required for the inter-page processing, no wait time is required. Even if any wait time is required, the decrease in the time required for the ejection failure state sensing process 7B serves to reduce the total time required for the printing operation and the ejection failure state sensing process. Thus, the printing throughput can be improved.
The “ink” or the “liquid” needs to be broadly interpreted and refers to a liquid applied onto a print medium to form an image, a pattern, or the like, process the print medium, or treat the ink or the print medium. Here, the treatment of the ink or the print medium refers to, for example, improvement of fixability of the ink resulting from solidification or insolubilization of a color material in the ink, improvement of print quality or coloring capability, or improvement of image durability. Furthermore, the term “printing” as used herein means not only application of a meaningful image such as characters or figures onto the print medium but also application of a meaningless image such as a pattern onto the print medium.
Furthermore, in the above-described embodiments, one page of print medium is formed by cutting roll paper into pieces each with a predetermined length. However, the print medium may be print sheets each preformed to have a predetermined size. In this case, the inter-page processing is between the step in which a printing onto a print medium is performed, then the printed print medium is conveyed, and the step in which the next print medium to be printed is placed in a print area.
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. 2009-148830, filed Jun. 23, 2009, which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2009-148830 | Jun 2009 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 6527358 | Kuriyama et al. | Mar 2003 | B2 |
| 20070229578 | Yokozawa et al. | Oct 2007 | A1 |
| 20070229591 | Konno | Oct 2007 | A1 |
| Number | Date | Country |
|---|---|---|
| 3382526 | Dec 2002 | JP |
| 2007-290352 | Nov 2007 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20100321431 A1 | Dec 2010 | US |
