FIELD OF THE INVENTION
[0001] The invention relates to a curing method for an inkjet printing apparatus. The curing
method includes partial and final curing steps.
BACKGROUND ART
[0002] Patent application PCT/
WO 2004002746 A (INCA DIGITAL PRINTERS LTD) published on 8 January 2004 discloses partial and final
curing of ink droplets deposited by inkjet printing.
[0003] In this patent application, curable ink is deposited in a plurality of passes. Immediately
after the deposition of ink in a particular pass, the ink is partially cured by a
"partial cure lamp" (34 in Figure 2 of this patent application).
[0004] When all ink has been jetted for a particular area of the printing surface, and all
this ink has been partially cured, that particular area passes under a "final cure
lamp" (36 in Figure 2 of this patent application) that effectuates a final curing
of the deposited ink.
[0005] Said application only discloses unidirectional printing. Patent application
EP 06122346 (AGFA-GEVAERT N.V.) filed on 16 October 2006 teaches bidirectional printing of a
curable ink.
[0006] Gloss banding refers to bands having different diffuse or specular reflection and
that are correlated with the different printing passes of a print head during printing.
[0007] We have found that prior art curing techniques result in a gloss banding problem
- both if unidirectional and bidirectional printing are used.
SUMMARY OF THE INVENTION
[0008] The problem of gloss banding is solved by a method and a system having the specific
features set out in claim 1 and the other independent and dependent claims of the
current application.
[0009] We have observed that the invention apparently results in a more even gloss level
of a print and that the overall gloss level is apparently increased.
[0010] According to the present invention and referring to Figure 7, printing of an image
is organized in two sets 710, 740 of printing passes.
[0011] In a first set 710 of printing passes, a printing pass 720 is followed by a partial
curing step 730 during which the printed ink can partially solidify.
[0012] In a second set 740 of printing passes, a printing pass 750 is specifically not followed
by a partial curing step.
[0013] When all printing passes are finished, the printed image is subject to a final curing
step 770.
[0014] Preferably, the positions of the pixels printed in said first and said second set
of passes are mutually interstitial.
[0015] Preferably the multiple passes comprise interlacing to increase the printing resolution
in slow scan orientation.
[0016] Preferably the multiple passes comprise shingling to reduce correlated image quality
artifacts, such as streaking and banding parallel to a fast scan orientation.
[0017] Preferably, the inks are UV-curable inks and curing is established by means of UV-curing
lamps.
[0018] Preferably, the positions of the pixels printed in said first set of print passes
have a diagonal orientation with regard to a fast and a slow scan orientation of a
printer.
BRIEF DESCRIPTION OF FIGURES IN DRAWINGS
[0019] Figure 1 shows a printing system comprising three stations that can be used to carry
out a method according to the current invention.
[0020] Figure 2 shows a print head assembly comprising four print heads and two partial
cure lamps that can be used to carry out a method according to the current invention.
[0021] Figure 3 shows a multiple print head configuration comprising two print heads printing
with the same ink.
[0022] Figure 4 is used to explain how in a preferred embodiment of the current invention
printing with multiple passes can reduce correlated image quality artifacts.
[0023] Figure 5A to 5D show a preferred embodiment of printing mutually interstitial images
using multiple printing passes such as streaking and banding.
[0024] Figure 6 further explains a preferred embodiment of using multiple printing passes.
[0025] Figure 7 shows the steps of a method according to a preferred embodiment of the current
invention.
TERMINOLOGY
printing
[0026] The method according to the current invention is mainly directed towards the use
in dot matrix printers and specifically drop-on-demand inkjet printers, but it is
not limited thereto. The term printing as used in the invention refers to the process
of creating a structured pattern of ink markings on a substrate to render an original
image, for example an image of a document. Non-impact printing methods are preferred
but the present invention is not limited thereto.
[0027] Referring to Figure 1, printing an image of a document in a station 120 (Figure 1)
can be achieved by moving a marking element 123 mounted on a shuttle 122 relative
to a substrate 121 and selectively marking the substrate in response to pixel values
of a digital image of said document.
[0028] For this purpose, the shuttle 122 is designed to move along a fast scan orientation
124, 125 and a slow scan orientation 128, 129.
[0029] To improve printing performance, a printing system may not comprise one single marking
element but a plurality of marking elements - for example arranged in an array - that
can be operated in parallel and that together make up a print head.
[0030] Referring to Figure 3, printing performance may be improved even more by operating
multiple print heads 301, 302 in parallel.
substrate
[0031] The substrate on which is printed could be paper, but it could also be textile, a
synthetic foil or a metal plate. It can be made available in sheets or on a web.
ink
[0032] An ink is a substance that is selectively deposited by a printing device on the substrate
to render an image.
[0033] The ink could be a pigmented or dyed colorant but it could also be wax, a water repellent
substance, an adhesive, or a polymer that is printable.
[0034] Usually ink is not a pure compound, but a complex mixture comprising several components
such as dyes, pigments, surfactants, binders, fillers, solvents, water, and dispersants
- each component serving a specific function.
partial and final curing
[0035] A curable ink shall refer to an ink that undergoes a phase change under the influence
of an external energy source that is specifically used for this purpose. The external
energy source could for example be an IR light or a UV light source.
[0036] An ink that is printed on a substrate and that is not cured can exhibit coalescence.
Coalescence is a physical process in which ink markings on a substrate that physically
connect start to fuse. This is sometimes referred to as "bleeding."
[0037] An ink can be partially cured or completely cured.
[0038] A partially cured ink printed on a substrate has been solidified to the point that
it does not coalesce anymore, but still requires additional curing to obtain a rub
resistance that is needed for the intended application of a the printed product.
[0039] A completely cured ink on a printed substrate is sufficiently solidified so that
it has a rub resistance that is sufficient for the intended application of the printed
product.
interstitial printing - interlacing shingling
[0040] The application
EP 06122346.7 filed on 16 October 2006 by the same applicant as the current invention teaches a method in which pixels having
positions on a given row or column in an image are printed in multiple printing passes.
[0041] Printing in multiple passes enables to achieve at least two objectives.
[0042] A first objective is to increase the resolution of a printer with regard to the intrinsic
resolution of the print heads in a slow scan orientation.
[0043] Referring to Figure 2, the intrinsic resolution of a print head 204 in a slow scan
orientation 128, 129 is defined by the nozzle pitch 221. By printing in two passes,
whereby the print head in a second pass is shifted over half the nozzle pitch 221
(or a multiple thereof) in a slow scan orientation 128, 129, it is possible to double
the print resolution along this orientation 128, 129. This technique to increase the
printing resolution in a slow scan orientation by a multiple factor is sometimes referred
to as "interlacing."
[0044] An "interlacing factor" designates an integer multiple factor by which the resolution
in a slow scan orientation is increased by using interlaced multiple pass printing.
[0045] A second objective of printing in multiple passes is to suppress artifacts that are
correlated with individual nozzles of a print head.
[0046] Differences in jetting characteristics between individual nozzles can result in streaking
or banding artifacts.
[0047] Referring to Figure 4, a solution to this problem consists of printing the pixels
on a line 410 parallel to a fast scan orientation 124, 125 alternately by two nozzles
420 and 421. This has the effect that the correlated artifacts caused by each individual
nozzle 420, 421 are averaged out and become less noticeable.
[0048] Practically the method is realized by:
- printing in a first pass a first one 440 out of two pixels 440, 441 on a line 410
parallel to a fast scan orientation 124, 125 by a print head 401,
- shifting said print head 401 over a distance 430, and
- printing in a second pass a second one 441 out of two pixels 440, 441 on the same
line 410.
[0049] The same principle is easily extended to average out correlated artifacts between
more than two different two nozzles, for example between four nozzles.
[0050] The just described technique for reducing correlated image quality artifacts is sometimes
referred to as "shingling."
[0051] A "shingling factor" indicates the number of different nozzles that are used to print
the pixels on a given line in a fast scan orientation. In the example shown in Figure
4, a shingling factor equals two.
[0052] Technically both interlacing and shingling are realized by separating an image that
is to be printed in mutually interstitial images, and printing these mutually interstitial
images in different passes, whereby the print head is moved in directions 128, 128
between the different printing passes.
DETAILED DESCRIPTION OF THE CURRENT INVENTION
description of a system
[0053] Figure 1 shows a system 100 that can be used for carrying out a method according
to the current invention.
[0054] The system comprises a first station 110, a second station 120, and a third station
130.
[0055] A first station 110 holds a stack of unprinted substrate 111.
[0056] In a first step, a sheet 111 of the unprinted substrate is moved by a first substrate
transport mechanism (not shown in Figure 1) from the first station 110 in a direction
140 to the second station 120.
[0057] In a next step, an image is printed with ink on the sheet in station 120. During
this step, the ink on the printed sheet 121 is also partially cured.
[0058] The printing of the image is achieved by means of multiple inkjet print heads 123
that are part of a print head assembly 123 mounted on a shuttle 122 that moves bidirectionally
along a fast scan orientation 124 and 125.
[0059] Because the size of a print head 126, 127 is generally less than the size of a sheet
121, the shuttle with the print head assembly can also move along a slow scan orientation
128, 129 so that the whole area of a sheet 121 can be printed on. This also enables
to print an image in multiple printing passes using interlacing and shingling.
[0060] The partial curing is preferably achieved by means of partial curing lamps 126, 127
that are preferably also mounted on shuttle 122.
[0061] In a third step, the printed sheet 121 is moved by a second substrate transport mechanism
(not shown in Figure 1) in a direction 141 to the third station 130. In this third
station 130, the ink on the substrate undergoes a final curing step.
[0062] The final curing is achieved by means of final curing lamps 133,134 mounted on a
shuttle 132 that moves bidirectionally in the directions 140 and 141.
[0063] Optionally, the printed and cured sheet is moved in a fourth step from the third
station 130 to a fourth station (not shown on Figure 1) where it is stacked.
[0064] A printing system that is used for the current invention also comprises a printer
controller to control the different sensors and actuators of the system and a raster
image processor to calculate a digital image having pixels of a document that is to
be printed.
[0065] These peripheral components are not elaborated here, as they are known to a person
skilled in the art.
print head and print head assembly
[0066] Figure 2 shows a preferred embodiment of a print head assembly wherein the numbers
201 to 204 each correspond with individual print heads printing cyan (C), magenta
(M), yellow (Y) and black (K) inks and wherein the numbers 126 and 127 correspond
with partial curing lamps.
[0067] In the embodiment shown in Figure 2, an individual print head 201 has an array comprising
two rows 260, 261 of inkjet nozzles. The electronic drivers of the nozzles are preferably
adapted so that the droplets ejected by nozzles on rows 260, 261 land on the same
line parallel to a slow scan orientation 128, 129 on the substrate. The distance between
two adjacent nozzles measured along a slow scan orientation 128, 129 corresponds with
a nozzle pitch 221.
[0068] According to a preferred embodiment of the current invention, the ink is a UV curable
ink, i.e. it solidifies under the influence of a UV radiation source. The solidification
is preferably caused by a polymerization process that is initiated by the exposure
to the UV radiation source.
[0069] According to a preferred embodiment of the current invention, the addressable grid
of pixels is not a traditional rectangular grid of addressable pixels, but rather
a checkerboard type of addressable grid.
[0070] This is exemplified by Figure 5D in the current application, where the pixels having
positions 501, 502, 503 and 503 form a checkerboard pattern.
[0071] According a preferred embodiment of the current invention and referring to Figures
5A to 5D of the current application, an image that is to be printed is separated into
four mutually interstitial images that are printed in separate passes. A method for
separating an image into mutually interstitial images is explained by means of Figure
10 in the application
EP05104466.7 filed on 5 May 2005 by the same applicant as the current invention.
[0072] A first pass (Figure 5A) is followed by a second pass (Figure 5B) and results in
the printing of ink at the positions of the pixels 501, 502 that are laid out on diagonal
lines with regard to the fast and slow scan orientation of the printer.
[0073] These first and second passes form a first set of passes.
[0074] According to a preferred embodiment of the current invention, the printed ink at
the positions of the pixels 501 and 502 in said first set of passes receives a partial
curing.
[0075] A third and a fourth pass further fill in ink at the positions of the pixels 503,
504.
[0076] These third and fourth passes form a second set of printing passes.
[0077] According to a preferred embodiment of the current invention, the ink printed at
the positions of the pixels 503, 504 in said second set of passes receives no partial
curing.
[0078] In a next step, the ink of the completely printed image receives a final curing.
[0079] The printing of the four passes can also be explained in more detail by means of
Figure 6.
[0080] The directions 124, 125 correspond with a fast scan orientation and the directions
128, 129 with a slow scan orientation.
[0081] Print head 600 has a nozzle pitch 640 and a length 642 of ten times the nozzle pitch.
Printing resolution is doubled by using interlacing having an interlacing factor of
two, so that the distance 641 between two printed lines is half the nozzle pitch 640.
[0082] The printing is organized in print cycles, each print cycle comprising two sets of
two printing passes.
[0083] At the beginning of a first print cycle, print head 600 is at a first starting position
601 along the slow scan orientation 128, 129. During the first printing pass, the
print head 600 moves in a fast scan direction 124 and prints ink at pixels having
positions indicated by a "1" on Figure 6.
[0084] According to said preferred embodiment, the ink printed at pixels having positions
indicated by "1" receives a partial curing step from lamp 126 (Figure 1) during the
first pass.
[0085] Before starting a second printing pass, print head 600 is shifted over a distance
630 - of for example half a nozzle pitch - from the first position 601 to a second
position 602 in the slow scan direction 129. During the second printing pass, the
print head 600 moves in a fast scan direction 125 and prints ink at pixels having
positions indicated by a "2" on Figure 6.
[0086] According to said preferred embodiment, the ink printed at pixels having positions
indicated by "2" receives a partial curing step from lamp 127 (Figure 1) during the
second pass. Because the lamp 127 produces a diffuse radiation, the printed ink at
pixels having positions indicated by "1" also receives a second partial curing step.
[0087] Optionally
both the lamps 126 and 127 are used for partial curing during the first and second printing
passes.
[0088] The first and the second printing pass together form a first set of printing passes
that include a partial curing step.
[0089] Before starting a third printing pass, print head 600 is shifted over a distance
631 - of for example two and half times a nozzle pitch 640 - from the second position
602 to a third position 603 in a slow scan direction 128. During the third printing
pass, the print head 600 moves again in a fast scan direction 124 and prints ink at
pixels having positions indicated by a "3" on Figure 6.
[0090] According to said preferred embodiment, the printed ink at pixels having positions
indicated by "3" specifically does
not receive a partial curing step from either lamp 126 or 127 (Figure 1) during the third
pass.
[0091] Before starting a fourth printing pass, print head 600 is shifted over a distance
632 - of for example half a nozzle pitch 640 - from the third position 603 to a fourth
position 604 in a slow scan direction 129. During the fourth printing pass, the print
head 600 moves in a fast scan direction 125 and prints ink at pixels having positions
indicated by a "4" on Figure 6.
[0092] According to said preferred embodiment, also the printed ink at pixels having positions
indicated by "4" specifically does
not receive a partial curing step from either lamp 126 or 127 (Figure 1) during the fourth
pass.
[0093] The third and fourth printing passes together form a second set of printing passes
that include no partial curing step.
[0094] After a first cycle of first four passes, print head 600 is shifted over a distance
633 - of for example twelve and half times a nozzle pitch - from the fourth to a fifth
position in a slow scan direction 129. This fifth position is the starting position
for a second cycle of four passes and that works in the same way as the first cycle
of four passes.
[0095] The cycles continue until the whole page is printed.
[0096] After a last cycle, the ink on the printed sheet receives a final curing.
[0097] This is realized in a third station 130 (Figure 1) by moving the two lamps 133, 134
mounted on a shuttle 132 bidirectionally over the printed sheet 131 in the directions
140, 141.
[0098] The shifting distances 630, 631, 632 and 633 are preferably selected taking into
account specific constraints.
[0099] According to a preferred embodiment, a first constraint is that the first two positions
601 and 602 address lines that are relatively interlaced.
[0100] This constraint has the effect that after the first two passes a set of pixels has
been addressed that are contiguously oriented along diagonal lines as indicated by
610 in Figure 6.
[0101] A similar constraint to achieve a similar effect is that the positions 603 and 604
also preferably address lines that are relatively interlaced.
[0102] According to the same preferred embodiment, the shifts 630, 631, 632 and 633 are
selected so that after each print cycle the position 605 of print head 600 is exactly
the print head length plus one nozzle pitch located from the position 601 of print
head 600 in a previous print cycle.
[0103] In Figure 6, for example, the print head length equals ten times the nozzle pitch
640 and the sum of the distances 630, 631, 632 and 633 equals eleven times the nozzle
pitch 640.
[0104] Yet another constraint is that preferably the print head positions 603 and 604 are
far enough from the print head positions 601 and 602, to avoid that partial curing
of ink at pixel positions "1" and "2" printed in a second cycle results in some partial
curing of the pixels having positions "3" and "4" printed in a first cycle as a result
of stray light from the partial cure lamps.
[0105] We have found that the above preferred embodiment solves the problem of gloss banding
in a prior art technique that uses partial curing after each print step.
[0106] In a prior art technique, ink printed at pixels in a first pass of a cycle is four
times partially cured, while ink printed at pixels in a fourth pass of the same cycle
is only once partially cured. This difference in number of partial curing steps between
different passes apparently results in a gloss of the final printed result that is
correlated with the different printing passes and that has the effect of gloss banding.
[0107] By not applying a partial curing during a third and fourth printing step, the ink
that is deposited during third and fourth printing passes is in exactly the same curing
condition before it is subject to a final curing step. We have observed that this
apparently results in a more even gloss level and an apparent reduction of the gloss
banding problem.
[0108] One could wonder if it would not be advantageous to apply no partial curing at all
- i.e. not even after the first and second printing passes - to obtain an even more
even gloss level and even less gloss banding.
[0109] It was found, however, that this latter approach results in more coalescence, which
is undesirable.
[0110] The partial curing of ink on pixels printed in a first set of passes has apparently
the effect of forming a matrix of partially cured ink droplets that inhibit coalescence
of ink droplets on pixels printed in a subsequent set of passes, even if the ink printed
in the subsequent set of passes is not partially cured.
[0111] What this means is that applying a partial curing during a first set of printing
passes but not during a second set of printing passes apparently enables to reduce
gloss banding while at the same time it avoids coalescence.
EXAMPLE
[0112] An example of the current invention uses the following parameters:
overall configuration
[0113] The overall configuration is the one shown in Figure 1 and as previously explained.
inkjet heads:
[0114] Four inkjet print heads are used, printing with cyan 203, magenta 202, yellow 201
and black 204 inks, and relatively arranged on a print head assembly 122 as indicated
in Figure 2.
[0115] Each head has 382 nozzles, arranged in two rows 260, 261 spaced at 70,6 micrometer
(1/360 inch) in a staggered configuration. The nozzle pitch 221 is also equal to 70,6
micrometer (1/360 inch).
[0116] The shuttle speed in the fast scan orientation 124, 125 is approximately 1 m/sec
and the firing speed of the inkjet heads is adjusted so that distance between two
neighboring ink droplets printed in one pass on the substrate has a distance of 70,6
micrometer (1/360 inch).
shingling and interlacing
[0117] The interlacing factor is two, resulting in a printing resolution in the slow scan
orientation 128, 129 of 283 pixels per cm (720 pixels per inch).
[0118] The shingling factor is also two, resulting in a printing resolution in the fast
scan orientation 124, 125 of 283 pixels per cm (720 pixels per inch).
[0119] These shingling and interlacing factors result in four passes per print cycle.
substrate
[0120] The printing substrate is double-sided matte coated paper sheet, 150 g/m
2, having a size of 266 cm by 165 cm, aligned with its largest dimension in the fast
scan orientation 124, 125 of the second station (Figure 1).
ink
[0121] The ink is the Anuvia UV-curable ink as manufactured and marketed in November 2006
by Agfa-Gevaert N.V. in Belgium.
curing
[0122] Partial curing is achieved by means of a pair of standard mercury arc tube lamps
126, 127 mounted on shuttle 122. A first lamp 126 is mounted on one side of print
heads 123 and a second lamp 127 is mounted on the other side.
[0123] Each partial curing lamp is rated at an electrical power of 70W/cm. The distance
between the heart of each tube lamp and the substrate is approximately 4 cm and each
lamp is provided with a reflector/diffuser to reflect and diffuse the radiation in
the direction of the substrate. The distances between the print heads and the lamps
are indicated on Figure 2.
[0124] The lamps are operated in binary mode, i.e. the lamps can be switched off, or on
in which latter case the lamps produce 100% of their rated power. Preferably, the
lamps are switched off by means of a shutter that is controlled by means of a printer
controller.
[0125] Partial curing takes place during the first set of two printing passes of a cycle,
while no partial curing takes place during the second set of two printing passes of
a cycle.
[0126] Final curing is achieved by means of a combination of a single standard mercury arc
lamp 133 having an electrical power of 120 W/cm with a single iron doped mercury arc
lamp 134 also having an electrical power of 120W/cm both mounted on shuttle 132. Both
lamps have a reflector/diffuser. The lamps are mounted approximately 10 cm above the
substrate and can be switched off or on to 100% of their nominal power. The shuttle
132 moves at approximately 30 cm/sec and curing takes place both during a first pass
in a direction 140 and during a second pass in a direction 141.
OTHER EMBODIMENTS
[0127] The above embodiment is one example of a method and a system that solves the problem
of gloss banding in the prior art, but many variations exist that use the same invention
and achieve the same advantageous effects.
[0128] A first important variation relates to the actual printing order of the different
passes. Referring to Figure 6, a print cycle as explained in a preferred embodiment
consists of printing in order:
- FIRST CYCLE
o pixels "1" on even row numbers 0 to 20;
o pixels "2" on odd row numbers 1 to 21;
o pixels "3" on even row numbers 0 to 16;
o pixels "4" on odd row numbers 1 to 17;
- SECOND CYCLE
o pixels "1" on even row numbers 22 to 42;
o pixels "2" on odd row numbers 23 to 43;
o pixels "3" on even row numbers 18 to 38;
o pixels "4" on odd row numbers 19 to 39;
- THIRD CYCLE
o etc.
[0129] In an alternative embodiment, the order of the printing passes is changed so that
all the pixels "1" and "2" are printed over the complete area of the page using partial
curing, followed by printing all the pixels "3" and "4" over the area without partial
curing. The printing order in that case would be:
- pixels "1" on even rows, complete page, partial curing
- pixels "2" on odd rows, complete page, partial curing
- pixels "3" on even rows, complete page, no partial curing
- pixels "4" on odd rows, complete page, no partial curing
[0130] This alternative embodiment achieves the same effect as the prior embodiment, i.e.
that the pixels "1" and "2" are printed and receive partial curing, while the pixels
"3" and "4" are printed and receive no partial curing.
[0131] To improve printing performance, an alternative print head assembly may comprise
not one but a plurality of print heads that print in parallel with the same ink.
[0132] An example of such an arrangement is shown in Figure 3 and uses for a given ink two
print heads. The two print heads are mounted so that their nozzles print on the same
line. The distance 304 between the two print heads equals the length 303 of each print
head. In yet another arrangement, the configuration as shown in Figure 3 is repeated
so that sixteen print heads are mounted so that their nozzles print on the same line,
with fifteen gaps in etween, each gap 304 between two print heads being equal to the
length 303 of each print head.
[0133] The arrangement shown in Figure 3 results in a doubling of the number of printing
passes per print cycle compared to the arrangement shown in Figure 2, which shows
a page-wide print head. This is because additional print passes are needed to make
up for the "missing nozzles" that exist between the two print heads 301, 302.
[0134] Another example of a variation of the current invention is to use the same lamps
for partial and for final curing. In that case a controller is preferably capable
to modulate the intensity of the lamps so that the intensity of the lamps is different
for partial and for final curing. Alternatively, not the intensity of lamps is modulated
to achieve this purpose, but the speed of the shuttle in the fast scan orientation.
[0135] The invention may be carried out using any combination of printing passes that comprises
at least a first set comprising at least one printing pass and at least a second set
also comprising at least one printing pass, wherein each printing pass of the first
set is followed by a partial curing step whereas each printing pass of the second
set is not followed by a partial curing step, as shown in Figure 7.
[0136] In a particular embodiment, one or more additional printing passes without partial
curing are carried out before the first set of printing passes 710 shown in Figure
7.
[0137] Specifically mentioned is the case of a print head configuration as illustrated in
Figure 3 and having sixteen print heads as discussed in connection with Figure 3,
and that uses eight printing passes for each area of the substrate that has to be
printed. According to one possible embodiment, a first set of printing passes during
which partial curing takes place comprises the first two of these eight printing passes.
According to another embodiment, said first set comprises four printing passes. According
to yet another embodiment, said first set comprises six printing passes.