WO1996032265A1 - Imprimante video en couleurs et systeme cd photographique a imprimante integree - Google Patents
Imprimante video en couleurs et systeme cd photographique a imprimante integree Download PDFInfo
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- WO1996032265A1 WO1996032265A1 PCT/US1996/004907 US9604907W WO9632265A1 WO 1996032265 A1 WO1996032265 A1 WO 1996032265A1 US 9604907 W US9604907 W US 9604907W WO 9632265 A1 WO9632265 A1 WO 9632265A1
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- ink
- drop
- nozzles
- printing
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B41—PRINTING; LINING MACHINES; TYPEWRITERS; STAMPS
- B41J—TYPEWRITERS; SELECTIVE PRINTING MECHANISMS, i.e. MECHANISMS PRINTING OTHERWISE THAN FROM A FORME; CORRECTION OF TYPOGRAPHICAL ERRORS
- B41J2/00—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed
- B41J2/005—Typewriters or selective printing mechanisms characterised by the printing or marking process for which they are designed characterised by bringing liquid or particles selectively into contact with a printing material
- B41J2/01—Ink jet
- B41J2/135—Nozzles
- B41J2/14—Structure thereof only for on-demand ink jet heads
- B41J2/14451—Structure of ink jet print heads discharging by lowering surface tension of meniscus
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04N—PICTORIAL COMMUNICATION, e.g. TELEVISION
- H04N1/00—Scanning, transmission or reproduction of documents or the like, e.g. facsimile transmission; Details thereof
- H04N1/23—Reproducing arrangements
Definitions
- the present invention is in the field of computer controlled printing devices.
- the field is thermally activated drop on demand (DOD) printing systems.
- DOD drop on demand
- the present invention is an apparatus for printing color images from a video signal.
- Color video printers can be used to obtain printed images, or 'hard copy', from various video sources. Examples of these sources are still video cameras, video cassette recorders, video camcorders, security cameras, video equipped computers, multi-media computers, broadcast television, cable television, and video-conferencing systems.
- Video printers have not yet become a high volume consumer item. One reason for slow acceptance of video printers is their high price relative to their perceived benefit Another reason is that video images typically look poor when printed larger than a 40 mm diagonal. This is due to the low resolution of video images. Another reason is the high print cost for each image printed, as many video printers require special paper or Dye Diffusion Thermal Transfer (D2T2) sheets. Slow print times have also been a factor in the low market acceptance of video printers. The major obstacle in the development of low cost, high quality video printers has been the lack of a suitable color printing mechanism.
- PhotoCD electronic photograph storage and viewing system
- This system uses writable CD-ROMs to store digital representations of photographic images. These images can be viewed using a television set, or can be transferred to a computer system and used for such purposes as desktop publishing.
- Eastman Kodak and other manufacturers are producing devices intended for the consumer market which allow the viewing of these digitally stored photographs on domestic television sets. These devices are called PhotoCD "players". These players allow the user to view photographs on a television set, but should the user require a print of one or more of the images, the PhotoCD must be taken to a suitably equipped photograph processing lab. Many consumers are likely to require the ability to make a print quickly, and on demand. This feature can be achieved by either connecting or incorporating a digital color printer into the PhotoCD player.
- there exists no color printing technology which is sufficiently low in cost and high in quality to produce a satisfactory solution to this problem.
- Inkjet printing has become recognized as a prominent contender in the digitally controlled, electronic printing arena because, e.g., of its non-impact, low-noise characteristics, its use of plain paper and its avoidance of toner transfers and fixing.
- Sweet et al US Pat. No. 3,373,437, 1967 discloses an array of continuous ink jet nozzles where ink drops to be printed are selectively charged and deflected towards the recording medium. This technique is known as binary deflection ClJ, and is used by several manufacturers, including Elmjet and Scitex.
- Hertz et al US Pat. No. 3,416,153, 1966 discloses a method of achieving variable optical density of printed spots in ClJ printing using the electrostatic dispersion of a charged drop stream to modulate the number of droplets which pass through a small aperture. This technique is used in inkjet printers manufactured by Iris Graphics.
- Kyser et al US Pat No. 3,946,398, 1970 discloses a DOD inkjet printer which applies a high voltage to a piezoelectric crystal, causing the crystal to bend, applying pressure on an ink reservoir and jetting drops on demand.
- Many types of piezoelectric drop on demand printers have subsequently been invented, which utilize piezoelectric crystals in bend mode, push mode, shear mode, and squeeze mode.
- Piezoelectric DOD printers have achieved commercial success using hot melt inks (for example, Tektronix and Dataproducts printers), and at image resolutions up to 720 dpi for home and office printers (Seiko Epson). Piezoelectric DOD printers have an advantage in being able to use a wide range of inks.
- piezoelectric printing mechanisms usually require complex high voltage drive circuitry and bulky piezoelectric crystal arrays, which are disadvantageous in regard to manufacturability and performance.
- DOD inkjet printer which applies a power pulse to an electrothermal transducer (heater) which is in thermal contact with ink in a nozzle.
- the heater rapidly heats water based ink to a high temperature, whereupon a small quantity of ink rapidly evaporates, forming a bubble.
- the formation of these bubbles results in a pressure wave which cause drops of ink to be ejected from small apertures along the edge of the heater substrate.
- BubblejetTM trademark of Canon K.K. of Japan
- Thermal Ink Jet printing typically requires approximately 20 ⁇ J over a period of approximately 2 ⁇ s to eject each drop.
- the 10 Watt active power consumption of each heater is disadvantageous in itself and also necessitates special inks, complicates the driver electronics and precipitates deterioration of heater elements.
- U.S. Patent No. 4,275,290 discloses a system wherein the coincident address of predetermined print head nozzles with heat pulses and hydrostatic pressure, allows ink to flow freely to spacer-separated paper, passing beneath the print head.
- U.S. Patent Nos. 4,737,803; 4,737,803 and 4,748,458 disclose ink jet recording systems wherein the coincident address of ink in print head nozzles with heat pulses and an electrostatically attractive field cause ejection of ink drops to a print sheet
- Apparatus and System and "Coincident Drop-Selection, Drop-Separation Printing Method and System” describe new methods and apparatus that afford significant improvements toward overcoming the prior art problems discussed above.
- Those inventions offer important advantages, e.g., in regard to drop size and placement accuracy, as to printing speeds attainable, as to power usage, as to durability and operative thermal stresses encountered and as to other printer performance characteristics, as well as in regard to manufacturability and the characteristics of useful inks.
- One important purpose of the present invention is to further enhance the structures and methods described in those applications and thereby contribute to the advancement of printing technology.
- the invention provides a color video printer using a drop on demand printing head operating on the concurrent drop selection and drop separation printing principle.
- a preferred form of the invention provides a color video printing apparatus comprising:
- a preferred aspect of the invention is that the bi-level printing mechanism is a single monolithic concurrent drop selection and drop separation printing head which can print to the full width of the photographic print
- a alternative preferred aspect of the invention is that the bi-level printing mechanism is composed of a plurality of monolithic concurrent drop selection and drop separation printing heads.
- a preferred aspect of the invention is that the print paper is in the form of pre-cut sheets.
- print paper is in the form of a continuous roll, and which incorporates an automatic paper cutter.
- a color video printing apparatus comprising:
- a digital halftoning unit which converts the continuous tone image data stored in the digital frame store to bi-level image data
- a preferred aspect of the invention is that the digital image processing unit removes inter-field motion artifacts from the digital image in the frame store.
- Another preferred aspect of the invention is that the digital image processing unit reduces image noise in the digital image in the frame store.
- the digital image processing unit digitally filters the digital image in the frame store.
- the digital image processing unit comprises a microprocessor or microcomputer, interface hardware, and image processing software.
- PhotoCD player incorporating a printing apparatus comprising:
- a data distribution and timing system which provides the bi-level image data to the printing head at the correct time during a printing operation; and 8) a bi-level printing mechanism operating on the concurrent drop selection and drop separation printing principle.
- Figure 1(a) shows a simplified block schematic diagram of one exemplary printing apparatus according to the present invention.
- Figure 1(b) shows a cross section of one variety of nozzle tip in accordance with the invention.
- Figures 2(a) to 2(f) show fluid dynamic simulations of drop selection.
- Figure 3(a) shows a finite element fluid dynamic simulation of a nozzle in operation according to an embodiment of the invention.
- Figure 3(b) shows successive meniscus positions during drop selection and separation.
- Figure 3(c) shows the temperatures at various points during a drop selection cycle.
- Figure 3(d) shows measured surface tension versus temperature curves for various ink additives.
- Figure 3(e) shows the power pulses which are applied to the nozzle heater to generate the temperature curves of figure 3(c)
- Figure 4 shows a block schematic diagram of print head drive circuitry for practice of the invention.
- Figure 5 shows projected manufacturing yields for an A4 page width color print head embodying features of the invention, with and without fault tolerance.
- Figure 6(a) shows a simplified schematic diagram of a color video printer using a concurrent drop selection and drop separation printing technology.
- Figure 6(b) shows a simplified schematic diagram of a PhotoCD player incorporating a printer using concurrent drop selection and drop separation printing technology.
- Figure 7(a) shows a top view of major component placement in one configuration of the printer.
- Figure 7(b) shows a side view of major component placement in one configuration of the printer.
- Figure 8 shows a perspective view of one possible configuration of the printer.
- a color video printer uses a drop on demand concurrent drop selection and drop separation printing mechanism.
- the system consists of a video digitizer, a digital video frame store, an optional digital image processing system, a digital halftoning unit a data phasing unit and a printing mechanism using liquid ink.
- the print is created in three stages. These are an image capture stage, where a single frame of a video signal is digitally captured in real-time and stored in a frame store.
- the second stage is an image processing stage, which may be implemented in software and is not required to occur in real time. The major functions of this stage are the removal of motion between the two fields of the video frame, image enhancement and optional image effects.
- the third stage is printing the image. In this stage continuous tone image information from the frame store is digitally halftoned and printed by the printing head.
- a user can view digitally encoded photographic images on a television set or video monitor.
- a television resolution version of the image is read from the PhotoCD, stored in semiconductor memory, decompressed, and displayed on the television monitor.
- the user can 'browse' through these images at will.
- a high resolution version of the image also stored on the PhotoCD, is accessed.
- This high resolution image is decompressed and converted to a bilevel image by vector error diffusion or an alternative form of digital halftoning, and stored in a bi-level image memory.
- the contents of the bi-level image memory are then printed using a LIFT printing head.
- the invention constitutes a drop-on-demand printing mechanism wherein the means of selecting drops to be printed produces a difference in position between selected drops and drops which are not selected, but which is insufficient to cause the ink drops to overcome the ink surface tension and separate from the body of ink, and wherein an alternative means is provided to cause separation of the selected drops from the body of ink.
- the separation of drop selection means from drop separation means significantly reduces the energy required to select which ink drops are to be printed.
- the drop separation means can be a field or condition applied simultaneously to all nozzles.
- the drop selection means may be chosen from, but is not limited to, the following list:
- the drop separation means may be chosen from, but is not limited to, the following list:
- DOD printing technology targets shows some desirable characteristics of drop on demand printing technology.
- the table also lists some methods by which some embodiments described herein, or in other of my related applications, provide improvements over the prior art DOD printing technology targets
- TlJ thermal ink jet
- piezoelectric ink jet systems a drop velocity of approximately 10 meters per second is preferred to ensure that the selected ink drops overcome ink surface tension, separate from the body of the ink, and strike the recording medium.
- These systems have a very low efficiency of conversion of electrical energy into drop kinetic energy.
- the efficiency of TlJ systems is approximately 0.02%).
- the drive circuits for piezoelectric inkjet heads must either switch high voltages, or drive highly capacitive loads.
- the total power consumption of pagewidth TlJ printheads is also very high.
- An 800 dpi A4 full color pagewidth TlJ print head printing a four color black image in one second would consume approximately 6 kW of electrical power, most of which is converted to waste heat. The difficulties of removal of this amount of heat precludes the production of low cost high speed, high resolution compact pagewidth TlJ systems.
- One important feature of embodiments of the invention is a means of significantly reducing the energy required to select which ink drops are to be printed. This is achieved by separating the means for selecting ink drops from the means for enstiring that selected drops separate from the body of ink and form dots on the recording medium. Only the drop selection means must be driven by individual signals to each nozzle. The drop separation means can be a field or condition applied simultaneously to all nozzles.
- Drop selection means shows some of the possible means for selecting drops in accordance with the invention.
- the drop selection means is only required to create sufficient change in the position of selected drops that the drop separation means can discriminate between selected and unselected drops.
- the preferred drop selection means for water based inks is method 1 : ' ⁇ lectrothermal reduction of surface tension of pressurized ink".
- This drop selection means provides many advantages over other systems, including; low power operation (approximately 1% of TlJ), compatibility with CMOS VLSI chip fabrication, low voltage operation (approx. 10 V), high nozzle density, low temperature operation, and wide range of suitable ink formulations.
- the ink must exhibit a reduction in surface tension with increasing temperature.
- the preferred drop selection means for hot melt or oil based inks is method 2: ' ⁇ lectrothe ⁇ nal reduction of ink viscosity, combined with oscillating ink pressure".
- This drop selection means is particularly suited for use with inks which exhibit a large reduction of viscosity with increasing temperature, but only a small reduction in surface tension. This occurs particularly with non-polar ink carriers with relatively high molecular weight This is especially applicable to hot melt and oil based inks.
- the table “Drop separation means” shows some of the possible methods for separating selected drops from the body of ink, and ensuring that the selected drops form dots on the printing medium.
- the drop separation means discriminates between selected drops and unselected drops to ensure that unselected drops do not form dots on the printing medium.
- the preferred drop separation means depends upon the intended use. For most applications, method 1: “Electrostatic attraction”, or method 2: “AC electric field” are most appropriate. For applications where smooth coated paper or film is used, and very high speed is not essential, method 3: “Proximity” may be appropriate. For high speed, high quality systems, method 4: 'Transfer proximity” can be used. Method 6: “Magnetic attraction” is appropriate for portable printing systems where the print medium is too rough for proximity printing, and the high voltages required for electrostatic drop separation are undesirable. There is no clear 'best' drop separation means which is applicable to all circumstances.
- FIG. 1 A simplified schematic diagram of one preferred printing system according to the invention appears in Figure 1(a).
- An image source 52 may be raster image data from a scanner or computer, or outline image data in the form of a page description language (PDL), or other forms of digital image representation.
- This image data is converted to a pixel-mapped page image by the image processing system 53.
- This may be a raster image processor (RIP) in the case of PDL image data, or may be pixel image manipulation in the case of raster image data.
- Continuous tone data produced by the image processing unit 53 is halftoned. Halftoning is performed by the Digital
- Halftoning unit 54 Halftoned bitmap image data is stored in the image memory 72.
- the image memory 72 may be a full page memory, or a band memory.
- Heater control circuits 71 read data from the image memory 72 and apply time-varying electrical pulses to the nozzle heaters (103 in figure 1(b)) that are part of the print head 50. These pulses are applied at an appropriate time, and to the appropriate nozzle, so that selected drops will form spots on the recording medium 51 in the appropriate position designated by the data in the image memory 72.
- the recording medium 51 is moved relative to the head 50 by a paper transport system 65, which is electronically controlled by a paper transport control system 66, which in turn is controlled by a microcontroller 315.
- the paper transport system shown in figure 1(a) is schematic only, and many different mechanical configurations are possible. In the case of pagewidth print heads, it is most convenient to move the recording medium 51 past a stationary head 50.
- the microcontroller 315 may also control the ink pressure regulator 63 and the heater control circuits 71.
- ink is contained in an ink reservoir 64 under pressure.
- the ink pressure is insufficient to overcome the ink surface tension and eject a drop.
- a constant ink pressure can be achieved by applying pressure to the ink reservoir 64 under the control of an ink pressure regulator 63.
- the ink pressure can be very accurately generated and controlled by situating the top surface of the ink in the reservoir 64 an appropriate distance above the head 50. This ink level can be regulated by a simple float valve (not shown).
- ink is contained in an ink reservoir 64 under pressure, and the ink pressure is caused to oscillate.
- the means of producing this oscillation may be a piezoelectric actuator mounted in the ink channels (not shown).
- the ink is distributed to the back surface of the head 50 by an ink channel device 75.
- the ink preferably flows through slots and/or holes etched through the silicon substrate of the head 50 to the front surface, where the nozzles and actuators are situated.
- the nozzle actuators are electrothermal heaters.
- an external field 74 is required to ensure that the selected drop separates from the body of the ink and moves towards the recording medium 51.
- a convenient external field 74 is a constant electric field, as the ink is easily made to be electrically conductive.
- the paper guide or platen 67 can be made of electrically conductive material and used as one electrode generating the electric field.
- the other electrode can be the head 50 itself.
- Another embodiment uses proximity of the print medium as a means of discriminating between selected drops and unselected drops.
- Figure 1(b) is a detail enlargement of a cross section of a single microscopic nozzle tip embodiment of the invention, fabricated using a modified CMOS process.
- the nozzle is etched in a substrate 101, which may be silicon, glass, metal, or any other suitable material. If substrates which are not
- a semiconducting material such as amorphous silicon
- integrated drive transistors and data distribution circuitry may be formed in the surface semiconducting layer.
- Single crystal silicon (SCS) substrates have several advantages, including:
- Print heads can be fabricated in existing facilities (fabs) using standard VLSI processing equipment;
- SCS has high mechanical strength and rigidity
- SCS has a high thermal conductivity
- the nozzle is of cylindrical form, with the heater 103 forming an annulus.
- the nozzle tip 104 is formed from silicon dioxide layers 102 deposited during the fabrication of the CMOS drive circuitry.
- the nozzle tip is passivated with silicon nitride.
- the protruding nozzle tip controls the contact point of the pressurized ink 100 on the print head surface.
- the print head surface is also hydrophobized to prevent accidental spread of ink across the front of the print head.
- nozzle embodiments of the invention may vary in shape, dimensions, and materials used.
- Monolithic nozzles etched from the substrate upon which the heater and drive electronics are formed have the advantage of not requiring an orifice plate.
- the elimination of the orifice plate has significant cost savings in manufacture and assembly.
- Recent methods for eliminating orifice plates include the use of 'vortex' actuators such as those described in Domoto et al US Pat. No. 4,580,158, 1986, assigned to Xerox, and Miller et al US Pat. No. 5,371,527, 1994 assigned to
- This type of nozzle may be used for print heads using various techniques for drop separation. Operation with Electrostatic Drop Separation
- Figure 2 shows the results of energy transport and fluid dynamic simulations performed using FIDAP, a commercial fluid dynamic simulation software package available from Fluid Dynamics Inc., of Illinois, USA.
- FIDAP Fluid Dynamics Inc.
- This simulation is of a thermal drop selection nozzle embodiment with a diameter of 8 ⁇ m, at an ambient temperature of 30°C.
- the total energy applied to the heater is 276 nJ, applied as 69 pulses of 4 nJ each.
- the ink pressure is 10 kPa above ambient air pressure, and the ink viscosity at 30°C is 1.84 cPs.
- the ink is water based, and includes a sol of 0.1 % palmitic acid to achieve an enhanced decrease in surface tension with increasing temperature.
- a cross section of the nozzle tip from the central axis of the nozzle to a radial distance of 40 ⁇ m is shown.
- Heat flow in the various materials of the nozzle including silicon, silicon nitride, amorphous silicon dioxide, crystalline silicon dioxide, and water based ink are simulated using the respective densities, heat capacities, and thermal conductivities of the materials.
- the time step of the simulation is 0.1 ⁇ s.
- Figure 2(a) shows a quiescent state, just before the heater is actuated. An equilibrium is created whereby no ink escapes the nozzle in the quiescent state by ensuring that the ink pressure plus external electrostatic field is insufficient to overcome the surface tension of the ink at the ambient temperature. In the quiescent state, the meniscus of the ink does not protrude significantly from the print head surface, so the electrostatic field is not significantly concentrated at the meniscus.
- Figure 2(b) shows thermal contours at 5°C intervals 5 ⁇ s after the start of the heater energizing pulse. When the heater is energized, the ink in contact with the nozzle tip is rapidly heated. The reduction in surface tension causes the heated portion of the meniscus to rapidly expand relative to the cool ink meniscus.
- Figure 2(c) shows thermal contours at 5°C intervals 10 ⁇ s after the start of the heater energizing pulse.
- the increase in temperature causes a decrease in surface tension, disturbing the equilibrium of forces. As the entire meniscus has been heated, the ink begins to flow.
- Figure 2(d) shows thermal contours at 5°C intervals 20 ⁇ s after the start of the heater energizing pulse.
- the ink pressure has caused the ink to flow to a new meniscus position, which protrudes from the print head.
- the electrostatic field becomes concentrated by the protruding conductive ink drop.
- Figure 2(e) shows thermal contours at 5°C intervals 30 ⁇ s after the start of the heater energizing pulse, which is also 6 ⁇ s after the end of the heater pulse, as the heater pulse duration is 24 ⁇ s.
- the nozzle tip has rapidly cooled due to conduction through the oxide layers, and conduction into the flowing ink.
- the nozzle tip is effectively 'water cooled' by the ink. Electrostatic attraction causes the ink drop to begin to accelerate towards the recording medium. Were the heater pulse significantly shorter (less than 16 ⁇ s in this case) the ink would not accelerate towards the print medium, but would instead return to the nozzle.
- Figure 2(f) shows thermal contours at 5°C intervals 26 ⁇ s after the end of the heater pulse.
- the temperature at the nozzle tip is now less than 5°C above ambient temperature. This causes an increase in surface tension around the nozzle tip.
- the rate at which the ink is drawn from the nozzle exceeds the viscously limited rate of ink flow through the nozzle, the ink in the region of the nozzle tip 'necks', and the selected drop separates from the body of ink.
- the selected drop then travels to the recording medium under the influence of the external electrostatic field.
- the meniscus of the ink at the nozzle tip then returns to its quiescent position, ready for the next heat pulse to select the next ink drop.
- One ink drop is selected, separated and forms a spot on the recording medium for each heat pulse. As the heat pulses are electrically controlled, drop on demand inkjet operation can be achieved.
- Figure 3(a) shows successive meniscus positions during the drop selection cycle at 5 ⁇ s intervals, starting at the beginning of the heater energizing pulse.
- Figure 3(b) is a graph of meniscus position versus time, showing the movement of the point at the centre of the meniscus.
- the heater pulse starts 10 ⁇ s into the simulation.
- Figure 3(c) shows the resultant curve of temperature with respect to time at various points in the nozzle.
- the vertical axis of the graph is temperature, in units of 100°C.
- the horizontal axis of the graph is time, in units of 10 ⁇ s.
- the temperature curve shown in figure 3(b) was calculated by FIDAP, using 0.1 ⁇ s time steps.
- the local ambient temperature is 30 degrees C. Temperature histories at three points are shown:
- a - Nozzle tip This shows the temperature history at the circle of contact between the passivation layer, the ink, and air.
- C - Chip surface This is at a point on the print head surface 20 ⁇ m from the centre of the nozzle. The temperature only rises a few degrees. This indicates that active circuitry can be located very close to the nozzles without experiencing performance or lifetime degradation due to elevated temperatures.
- Figure 3(e) shows the power applied to the heater.
- Optimum operation requires a sharp rise in temperature at the start of the heater pulse, a maintenance of the temperature a little below the boiling point of the ink for the duration of the pulse, and a rapid fall in temperature at the end of the pulse.
- the average energy applied to the heater is varied over the duration of the pulse. In this case, the variation is achieved by pulse frequency modulation of
- 0.1 ⁇ s sub-pulses each with an energy of 4 nJ.
- the peak power applied to the heater is 40 mW, and the average power over the duration of the heater pulse is 11.5 mW.
- the sub-pulse frequency in this case is 5 Mhz. This can readily be varied without significantly affecting the operation of the print head.
- a higher sub-pulse frequency allows finer control over the power applied to the heater.
- a sub-pulse frequency of 13.5 Mhz is suitable, as this frequency is also suitable for minimizing the effect of radio frequency interference (RFI).
- RFID radio frequency interference
- T is the surface tension at temperature T
- k is a constant T c is the critical temperature of the liquid
- M is the molar mass of the liquid
- x is the degree of association of the liquid
- p is the density of the liquid.
- surfactant is important
- water based ink for thermal inkjet printers often contains isopropyl alcohol (2-propanol) to reduce the surface tension and promote rapid drying.
- Isopropyl alcohol has a boiling point of 82.4°C, lower than that of water.
- a surfactant such as 1-Hexanol (b.p. 158°C) can be used to reverse this effect and achieve a surface tension which decreases slightly with temperature.
- a relatively large decrease in surface tension with temperature is desirable to maximize operating latitude.
- a surface tension decrease of 20 mN/m over a 30°C temperature range is preferred to achieve large operating margins, while as little as lOmN/m can be used to achieve operation of the print head according to the present invention.
- the ink may contain a low concentration sol of a surfactant which is solid at ambient temperatures, but melts at a threshold temperature. Particle sizes less than 1,000 A are desirable. Suitable surfactant melting points for a water based ink are between 50°C and 90°C, and preferably between 60°C and 80°C. 2)
- the ink may contain an oil/water microemulsion with a phase inversion
- PIT PIT temperature which is above the maximum ambient temperature, but below the boiling point of the ink.
- the PIT of the microemulsion is preferably 20°C or more above the maximum non-operating temperature encountered by the ink.
- a PIT of approximately 80°C is suitable.
- Inks can be prepared as a sol of small particles of a surfactant which melts in the desired operating temperature range.
- surfactants include carboxylic acids with between 14 and 30 carbon atoms, such as:
- the melting point of sols with a small particle size is usually slightly less than of the bulk material, it is preferable to choose a carboxylic acid with a melting point slightly above the desired drop selection temperature.
- a good example is Arachidic acid.
- carboxylic acids are available in high purity and at low cost
- the amount of surfactant required is very small, so the cost of adding them to the ink is insignificant
- a mixture of carboxylic acids with slightly varying chain lengths can be used to spread the melting points over a range of temperatures. Such mixtures will typically cost less than the pure acid.
- surfactant it is not necessary to restrict the choice of surfactant to simple unbranched carboxylic acids.
- Surfactants with branched chains or phenyl groups, or other hydrophobic moieties can be used. It is also not necessary to use a carboxylic acid.
- Many highly polar moieties are suitable for the hydrophilic end of the surfactant. It is desirable that the polar end be ionizable in water, so that the surface of the surfactant particles can be charged to aid dispersion and prevent flocculation. In the case of carboxylic acids, this can be achieved by adding an alkali such as sodium hydroxide or potassium hydroxide.
- the surfactant sol can be prepared separately at high concentration, and added to the ink in the required concentration.
- An example process for creating the surfactant sol is as follows: 1) Add the carboxylic acid to purified water in an oxygen free atmosphere. 2) Heat the mixture to above the melting point of the carboxylic acid. The water can be brought to a boil.
- the ink preparation will also contain either dye(s) or pigment (s), bactericidal agents, agents to enhance the electrical conductivity of the ink if electrostatic drop separation is used, humectants, and other agents as required.
- Anti-foaming agents will generally not be required, as there is no bubble formation during the drop ejection process.
- Inks made with anionic surfactant sols are generally unsuitable for use with cationic dyes or pigments. This is because the cationic dye or pigment may precipitate or flocculate with the anionic surfactant. To allow the use of cationic dyes and pigments, a cationic surfactant sol is required. The family of alkylamines is suitable for this purpose.
- the method of preparation of cationic surfactant sols is essentially similar to that of anionic surfactant sols, except that an acid instead of an alkali is used to adjust the pH balance and increase the charge on the surfactant particles.
- a pH of 6 using HCl is suitable.
- a microemulsion is chosen with a phase inversion temperature (PIT) around the desired ejection threshold temperature. Below the PIT, the microemulsion is oil in water (O/W), and above the PIT the microemulsion is water in oil (W/O). At low temperatures, the surfactant forming the microemulsion prefers a high curvature surface around oil, and at temperatures significantly above the PIT, the surfactant prefers a high curvature surface around water. At temperatures close to the PIT, the microemulsion forms a continuous 'sponge' of topologically connected water and oil.
- PIT phase inversion temperature
- the surfactant prefers surfaces with very low curvature.
- surfactant molecules migrate to the ink/air interface, which has a curvature which is much less than the curvature of the oil emulsion. This lowers the surface tension of the water.
- the microemulsion changes from O/W to W/O, and therefore the ink/air interface changes from water/air to oil/air.
- the oil/air interface has a lower surface tension.
- water is a suitable polar solvent.
- different polar solvents may be required.
- polar solvents with a high surface tension should be chosen, so that a large decrease in surface tension is achievable.
- the surfactant can be chosen to result in a phase inversion temperature in the desired range.
- poly(oxyethylene)alkylphenyl ether ethoxylated alkyl phenols, general formula:
- C n H 2n+1 C 4 H 6 (CH 2 CH 2 O) m OH) can be used.
- the hydrophilicity of the surfactant can be increased by increasing m, and the hydrophobicity can be increased by increasing n. Values of m of approximately 10, and n of approximately 8 are suitable.
- Synonyms include Octoxynol-10, PEG- 10 octyl phenyl ether and
- the HLB is 13.6, the melting point is 7°C, and the cloud point is
- ethoxylated alkyl phenols include those listed in the following table:
- Microemulsions are thermodynamically stable, and will not separate.
- the storage time can be very long. This is especially significant for office and portable printers, which may be used sporadically.
- microemulsion will form spontaneously with a particular drop size, and does not require extensive stirring, centrifuging, or filtering to ensure a particular range of emulsified oil drop sizes.
- the amoimt of oil contained in the ink can be quite high, so dyes which are soluble in oil or soluble in water, or both, can be used. It is also possible to use a mixture of dyes, one soluble in water, and the other soluble in oil, to obtain specific colors.
- Oil miscible pigments are prevented from flocculating, as they are trapped in the oil microdroplets.
- microemulsion can reduce the mixing of different dye colors on the surface of the print medium.
- Oil in water mixtures can have high oil contents - as high as 40% - and still form O/W microemulsions. This allows a high dye or pigment loading.
- the following table shows the nine basic combinations of colorants in the oil and water phases of the microemulsion that may be used.
- the ninth combination is useful for printing transparent coatings, UV ink, and selective gloss highlights.
- the absorption spectrum will tend to become broader, as the absorption peaks of both colorants are averaged. This has a tendency to 'muddy' the colors. To obtain brilliant color, careful choice of dyes and pigments based on their absorption spectra, not just their human-perceptible color, needs to be made. 2)
- the color of the ink may be different on different substrates. If a dye and a pigment are used in combination, the color of the dye will tend to have a smaller contribution to the printed ink color on more absorptive papers, as the dye will be absorbed into the paper, while the pigment will tend to 'sit on top' of the paper. This may be used as an advantage in some circumstances.
- This factor can be used to achieve an increased reduction in surface tension with increasing temperature. At ambient temperatures, only a portion of the surfactant is in solution. When the nozzle heater is turned on, the temperature rises, and more of the surfactant goes into solution, decreasing the surface tension.
- a surfactant should be chosen with a Krafft point which is near the top of the range of temperatures to which the ink is raised. This gives a maximum margin between the concentration of surfactant in solution at ambient temperatures, and the concentration of surfactant in solution at the drop selection temperature.
- the concentration of surfactant should be approximately equal to the
- the surface tension is reduced to the maximum amount at elevated temperatures, and is reduced to a minimum amount at ambient temperatures.
- Non-ionic surfactants using polyoxyethylene (POE) chains can be used to create an ink where the surface tension falls with increasing temperature.
- the POE chain is hydrophilic, and maintains the surfactant in solution.
- the structured water around the POE section of the molecule is disrupted, and the POE section becomes hydrophobic.
- the surfactant is increasingly rejected by the water at higher temperatures, resulting in increasing concentration of surfactant at the air/ink interface, thereby lowering surface tension.
- the temperature at which the POE section of a nonionic surfactant becomes hydrophilic is related to the cloud point of that surfactant POE chains by themselves are not particularly suitable, as the cloud point is generally above 100°C
- Polyoxypropylene (POP) can be combined with POE in POE/POP block copolymers to lower the cloud point of POE chains without introducing a strong hydrophobicity at low temperatures.
- Desirable characteristics are a room temperature surface tension which is as high as possible, and a cloud point between 40°C and 100°C, and preferably between 60°C and 80°C.
- Meroxapol [HO(CHCH 3 CH 2 O) x (CH 2 CH 2 O) y (CHCH 3 CH 2 O) z OH] varieties where the average x and z are approximately 4, and the average y is approximately 15 may be suitable.
- the cloud point of POE surfactants is increased by ions that disrupt water structure (such as I-), as this makes more water molecules available to form hydrogen bonds with the POE oxygen lone pairs.
- the cloud point of POE surfactants is decreased by ions that form water structure (such as Cl-, OH-), as fewer water molecules are available to form hydrogen bonds. Bromide ions have relatively little effect
- the ink composition can be 'tuned' for a desired temperature range by altering the lengths of POE and POP chains in a block copolymer surfactant and by changing the choice of salts (e.g Cl- to Br- to I-) that are added to increase electrical conductivity. NaCl is likely to be the best choice of salts to increase ink conductivity, due to low cost and non-toxicity. NaCl slightly lowers the cloud point of nonionic surfactants.
- the ink need not be in a liquid state at room temperature.
- Solid 'hot melt' inks can be used by heating the printing head and ink reservoir above the melting point of the ink.
- the hot melt ink must be formulated so that the surface tension of the molten ink decreases with temperature. A decrease of approximately 2 mN/m will be typical of many such preparations using waxes and other substances. However, a reduction in surface tension of approximately 20 mN/m is desirable in order to achieve good operating margins when relying on a reduction in surface tension rather than a reduction in viscosity.
- the temperature difference between quiescent temperature and drop selection temperature may be greater for a hot melt ink than for a water based ink, as water based inks are constrained by the boiling point of the water.
- the ink must be liquid at the quiescent temperature.
- the quiescent temperature should be higher than the highest ambient temperature likely to be encountered by the printed page. T he quiescent temperature should also be as low as practical, to reduce the power needed to heat the print head, and to provide a maximum margin between the quiescent and the drop ejection temperatures.
- a quiescent temperature between 60°C and 90°C is generally suitable, though other temperatures may be used.
- 200°C is generally suitable.
- substantially above the quiescent temperature, but substantially below the drop ejection temperature, can be added to the hot melt ink while in the liquid phase.
- a polar/non-polar microemulsion with a PIT which is preferably at least 20°C above the melting points of both the polar and non-polar compounds.
- the hot melt ink carrier have a relatively large surface tension (above 30 mN/m) when at the quiescent temperature. This generally excludes alkanes such as waxes. Suitable materials will generally have a strong intermolecular attraction, which may be achieved by multiple hydrogen bonds, for example, polyols, such as Hexanetetrol, which has a melting point of 88°C.
- Figure 3(d) shows the measured effect of temperature on the surface tension of various aqueous preparations containing the following additives:
- operation of an embodiment using thermal reduction of viscosity and proximity drop separation, in combination with hot melt ink is as follows.
- solid ink Prior to operation of the printer, solid ink is melted in the reservoir 64.
- the reservoir, ink passage to the print head, ink channels 75, and print head 50 are maintained at a temperature at which the ink 100 is liquid, but exhibits a relatively high viscosity (for example, approximately 100 cP).
- the Ink 100 is retained in the nozzle by the surface tension of the ink.
- the ink 100 is formulated so that the viscosity of the ink reduces with increasing temperature.
- the ink pressure oscillates at a frequency which is an integral multiple of the drop ejection frequency from the nozzle.
- the ink pressure oscillation causes oscillations of the ink meniscus at the nozzle tips, but this oscillation is small due to the high ink viscosity. At the normal operating temperature, these oscillations are of insufficient amplitude to result in drop separation.
- the heater 103 When the heater 103 is energized, the ink forming the selected drop is heated, causing a reduction in viscosity to a value which is preferably less than 5 cP. The reduced viscosity results in the ink meniscus moving further during the high pressure part of the ink pressure cycle.
- the recording medium 51 is arranged sufficiently close to the print head 50 so that the selected drops contact the recording medium 51, but sufficiently far away that the unselected drops do not contact the recording medium 51. Upon contact with the recording medium 51 , part of the selected drop freezes, and attaches to the recording medium.
- ink begins to move back into the nozzle.
- the body of ink separates from the ink which is frozen onto the recording medium.
- the meniscus of the ink 100 at the nozzle tip then returns to low amplitude oscillation.
- the viscosity of the ink increases to its quiescent level as remaining heat is dissipated to the bulk ink and print head.
- One ink drop is selected, separated and forms a spot on the recording medium 51 for each heat pulse. As the heat pulses are electrically controlled, drop on demand ink jet operation can be achieved.
- An objective of printing systems according to the invention is to attain a print quality which is equal to that which people are accustomed to in quality color publications printed using offset printing. This can be achieved using a print resolution of approximately 1,600 dpi. However, 1,600 dpi printing is difficult and expensive to achieve. Similar results can be achieved using 800 dpi printing, with 2 bits per pixel for cyan and magenta, and one bit per pixel for yellow and black. This color model is herein called CC MM'YK. Where high quality monochrome image printing is also required, two bits per pixel can also be used for black. This color model is herein called CC'MM'YKK'. Color models, halftoning, data compression, and real-time expansion systems suitable for use in systems of this invention and other printing systems are described in the following Australian patent specifications filed on 12 April 1995, the disclosure of which are hereby incorporated by reference:
- Printing apparatus and methods of this invention are suitable for a wide range of applications, including (but not limited to) the following: color and monochrome office printing, short run digital printing, high speed digital printing, process color printing, spot color printing, offset press supplemental printing, low cost printers using scanning print heads, high speed printers using pagewidth print heads, portable color and monochrome printers, color and monochrome copiers, color and monochrome facsimile machines, combined printer, facsimile and copying machines, label printing, large format plotters, photographic duplication, printers for digital photographic processing, portable printers incorporated into digital 'instant' cameras, video printing, printing of PhotoCD images, portable printers for 'Personal
- drop on demand printing systems have consistent and predictable ink drop size and position. Unwanted variation in ink drop size and position causes variations in the optical density of the resultant print, reducing the perceived print quality. These variations should be kept to a small proportion of the nominal ink drop volume and pixel spacing respectively. Many environmental variables can be compensated to reduce their effect to insignificant levels. Active compensation of some factors can be achieved by varying the power applied to the nozzle heaters.
- An optimum temperature profile for one print head embodiment involves an instantaneous raising of the active region of the nozzle tip to the ejection temperature, maintenance of this region at the ejection temperature for the duration of the pulse, and instantaneous cooling of the region to the ambient temperature.
- Figure 4 is a block schematic diagram showing electronic operation of an example head driver circuit in accordance with this invention.
- This control circuit uses analog modulation of the power supply voltage applied to the print head to achieve heater power modulation, and does not have individual control of the power applied to each nozzle.
- Figure 4 shows a block diagram for a system using an 800 dpi pagewidth print head which prints process color using the CC'MM' YK color model.
- the print head 50 has a total of 79,488 nozzles, with 39,744 main nozzles and 39,744 redundant nozzles.
- the main and redundant nozzles are divided into six colors, and each color is divided into 8 drive phases.
- Each drive phase has a shift register which converts the serial data from a head control ASIC 400 into parallel data for enabling heater drive circuits.
- Each shift register is composed of 828 shift register stages 217, the outputs of which are logically anded with phase enable signal by a nand gate 215.
- the output of the nand gate 215 drives an inverting buffer 216, which in turn controls the drive transistor 201.
- the drive transistor 201 actuates the electrothermal heater 200, which may be a heater 103 as shown in figure 1(b).
- the clock to the shift register is stopped the enable pulse is active by a clock stopper 218, which is shown as a single gate for clarity, but is preferably any of a range of well known glitch free clock control circuits. Stopping the clock of the shift register removes the requirement for a parallel data latch in the print head, but adds some complexity to the control circuits in the Head Control ASIC 400. Data is routed to either the main nozzles or the redundant nozzles by the data router 219 depending on the state of the appropriate signal of the fault status bus.
- the print head shown in figure 4 is simplified, and does not show various means of improving manufacturing yield, such as block fault tolerance.
- Digital information representing patterns of dots to be printed on the recording medium is stored in the Page or Band memory 1513, which may be the same as the Image memory 72 in figure 1(a).
- Data in 32 bit words representing dots of one color is read from the Page or Band memory 1513 using addresses selected by the address mux 417 and control signals generated by the Memory Interface 418.
- These addresses are generated by Address generators 411, which forms part of the 'Per color circuits' 410, for which there is one for each of the six color components.
- the addresses are generated based on the positions of the nozzles in relation to the print medium. As the relative position of the nozzles may be different for different print heads, the Address generators 411 are preferably made programmable.
- Address generators 411 normally generate the address corresponding to the position of the main nozzles. However, when faulty nozzles are present locations of blocks of nozzles containing faults can be marked in the Fault Map RAM 412. The
- Fault Map RAM 412 is read as the page is printed. If the memory indicates a fault in the block of nozzles, the address is altered so that the Address generators 411 generate the address corresponding to the position of the redundant nozzles.
- Data read from the Page or Band memory 1513 is latched by the latch 413 and converted to four sequential bytes by the multiplexer 414. Timing of these bytes is adjusted to match that of data representing other colors by the FIFO 415.
- This data is then buffered by the buffer 430 to form the 48 bit main data bus to the print head 50. The data is buffered as the print head may be located a relatively long distance from the head control ASIC.
- Data from the Fault Map RAM 412 also forms the input to the FIFO 416. The timing of this data is matched to the data output of the FIFO 415, and buffered by the buffer 431 to form the fault status bus.
- the programmable power supply 320 provides power for the head 50.
- the voltage of the power supply 320 is controlled by the DAC 313, which is part of a RAM and DAC combination (RAMDAC) 316.
- the RAMDAC 316 contains a dual port RAM 317.
- the contents of the dual port RAM 317 are programmed by the Microcontroller 315. Temperature is compensated by changing the contents of the dual port RAM 317. These values are calculated by the microcontroller 315 based on temperature sensed by a thermal sensor 300.
- the thermal sensor 300 signal connects to the Analog to Digital Converter (ADC) 311.
- ADC 311 is preferably incorporated in the Microcontroller 315.
- the Head Control ASIC 400 contains control circuits for thermal lag compensation and print density. Thermal lag compensation requires that the power supply voltage to the head 50 is a rapidly time- varying voltage which is
- the counter 403 may include a prescaler if the number of states in the count is less than the number of clock periods in one enable pulse. Sixteen voltage states are adequate to accurately compensate for the heater thermal lag. These sixteen states can be specified by using a four bit connection between the counter 403 and the dual port RAM 317. However, these sixteen states may not be linearly spaced in time. To allow non-linear timing of these states the counter 403 may also include a ROM or other device which causes the counter 403 to count in a non-linear fashion. Alternatively, fewer than sixteen states may be used.
- the printing density is detected by counting the number of pixels to which a drop is to be printed ('on' pixels) in each enable period.
- the 'on' pixels are counted by the On pixel counters 402.
- the number of enable phases in a print head in accordance with the invention depend upon the specific design. Four, eight and sixteen are convenient numbers, though there is no requirement that the number of enable phases is a power of two.
- the On Pixel Counters 402 can be composed of combinatorial logic pixel counters 420 which determine how many bits in a nibble of data are on. This number is then
- a latch 423 holds the accumulated value valid for the duration of the enable pulse.
- the multiplexer 401 selects the output of the latch 423 which corresponds to the current enable phase, as determined by the enable counter 404.
- the output of the multiplexer 401 forms part of the address of the dual port RAM 317. An exact count of the number of 'on' pixels is not necessary, and the most significant four bits of this count are adequate.
- Combining the four bits of thermal lag compensation address and the four bits of print density compensation address means that the dual port RAM 317 has an 8 bit address. This means that the dual port RAM 317 contains 256 numbers, which are in a two dimensional array. These two dimensions are time (for thermal lag compensation) and print density.
- a third dimension - temperature - can be included. As the ambient temperature of the head varies only slowly, the ambient temperature of the head varies only slowly, the ambient temperature of the head varies only slowly, the ambient temperature of the head varies only slowly, the ambient temperature of the head varies only slowly, the ambient temperature
- microcontroller 315 has sufficient time to calculate a matrix of 256 numbers compensating for thermal lag and print density at the current temperature.
- the microcontroller Periodically (for example, a few times a second), the microcontroller senses the current head temperature and calculates this matrix.
- the clock to the print head 50 is generated from the system clock
- JTAG test circuits 499 may be included.
- Invention compares the aspects of printing in accordance with the present invention with thermal ink jet printing technology.
- Thermal ink jet printers use the following fundamental operating principle.
- a thermal impulse caused by electrical resistance heating results in the explosive formation of a bubble in liquid ink. Rapid and consistent bubble formation can be achieved by superheating the ink, so that sufficient heat is transferred to the ink before bubble nucleation is complete.
- ink temperatures of approximately 280°C to 400°C are required.
- the bubble formation causes a pressure wave which forces a drop of ink from the aperture with high velocity. The bubble then collapses, drawing ink from the ink reservoir to re-fill the nozzle.
- thermal inkjet printing technology faces significant technical problems including multi-part precision fabrication, device yield, image resolution, 'pepper' noise, printing speed, drive transistor power, waste power dissipation, satellite drop formation, thermal stress, differential thermal expansion, kogation, cavitation, rectified diffusion, and difficulties in ink
- Printing in accordance with the present invention has many of the advantages of thermal inkjet printing, and completely or substantially eliminates many of the inherent problems of thermal ink jet technology.
- yield The percentage of operational devices which are produced from a wafer run is known as the yield. Yield has a direct influence on manufacturing cost. A device with a yield of 5% is effectively ten times more expensive to manufacture than an identical device with a yield of 50%.
- Figure 5 is a graph of wafer sort yield versus defect density for a monolithic full width color A4 head embodiment of the invention.
- the head is 215 mm long by 5 mm wide.
- the non fault tolerant yield 198 is calculated according to Murphy's method, which is a widely used yield prediction method. With a defect density of one defect per square cm, Murphy's method predicts a yield less than 1%. This means that more than 99% of heads fabricated would have to be discarded. This low yield is highly undesirable, as the print head manufacturing cost becomes unacceptably high.
- Figure 5 also includes a graph of non fault tolerant yield 197 which explicitly models the clustering of defects by introducing a defect clustering factor.
- the defect clustering factor is not a controllable parameter in manufacturing, but is a characteristic of the manufacturing process.
- the defect clustering factor for manufacturing processes can be expected to be approximately 2, in which case yield projections closely match Murphy's method.
- a solution to the problem of low yield is to incorporate fault tolerance by including redundant functional units on the chip which are used to replace faulty functional units.
- the physical location of redundant sub-units on the chip is not important
- the redundant sub-unit may contain one or more printing actuators. These must have a fixed spatial relationship to the page being printed.
- redimdant actuators must not be displaced in the non-scan direction.
- faulty actuators can be replaced with redundant actuators which are displaced in the scan direction.
- the data timing to the redundant actuator can be altered to compensate for the displacement in the scan direction.
- the minimum physical dimensions of the head chip are determined by the width of the page being printed, the fragility of the head chip, and manufacturing constraints on fabrication of ink channels which supply ink to the back surface of the chip.
- the minimum practical size for a full width, full color head for printing A4 size paper is approximately 215 mm x 5 mm. This size allows the inclusion of 100% redundancy without significantly increasing chip area, when using 1.5 ⁇ m CMOS fabrication technology. Therefore, a high level of fault tolerance can be included without significantly decreasing primary yield.
- Figure 5 shows the fault tolerant sort yield 199 for a full width color A4 head which includes various forms of fault tolerance, the modeling of which has been included in the yield equation.
- This graph shows projected yield as a function of both defect density and defect clustering. The yield projection shown in figure 5 indicates that thoroughly implemented fault tolerance can increase wafer sort yield from under 1% to more than 90% under identical manufacturing conditions. This can reduce the yield projection
- Fault tolerance is highly recommended to improve yield and reliability of print heads containing thousands of printing nozzles, and thereby make pagewidth printing heads practical. However, fault tolerance is not to be taken as an essential part of the present invention. Fault tolerance in drop-on-demand printing systems is described in the following Australian patent specifications filed on 12 April 1995, the disclosure of which are hereby incorporated by reference:
- the table "LIFT head type Photo-4-600” is a summary of some characteristics of an example full color monolithic printing head capable of printing a photograph size image at 600 dpi in one second.
- Figure 6 shows a schematic process diagram of a video printer using concurrent drop selection and drop separation printing technology. The blocks in this diagram represent discrete functions, irrespective of their implementations.
- Some of the blocks are electronic hardware, some are computer software, some are electromechanical units, and some are mechanical units. Some of the blocks are subsystems, which may include electronic hardware, software, mechanics, and optics.
- the image to be printed derives from a video source 525.
- This video source may be in any video format including PAL, NTSC, S-Video, RGB component video, CCIR601 digital video, or MAC.
- High resolution video sources such as HDTV, may also be used.
- Computer video formats such as VGA, SVGA, and workstation video outputs may also be used.
- Each video format requires conversion into a format suitable for storage in the digital frame store 529. This conversion is accomplished by the use of a video digitizer 526 and digital video decoder 527.
- the Philips TDA8708 is a suitable device for the video digitizer
- a Philips SAA7197 is a suitable digital decoder.
- Alternative configurations are possible.
- an analog decoder may be used.
- the output of this analog decoder may then be digitized using an analog to digital converter. If a direct digital video connection is used, then no analog to digital converter is required.
- Various video formats do not require a video decoder.
- An example is RGB component video, or analog RGB outputs from personal computers and workstations. In this case, only the video digitizer function is required. The design of systems for video digitizing is well known.
- the output of the video digitizer is raster format continuous tone image data, which may be in a 16 bit per pixel Y,Cr,Cb format, or a 24 bit RGB format, or other suitable frame storage format
- a single frame of digital video image information is stored in the digital frame store 529 at the user's request.
- This information may then optionally be processed by a digital image processing function 528.
- the digital image processing is not required to be a real-time process, so may readily be performed in software using a microprocessor.
- This microprocessor may be the control microcomputer 511, or may be a separate processor. If very high image processing speed is required, then the digital image processing functions may be performed by digital electronic hardware, which may be in the form of ASICs. Alternatively, a combination of digital electronic hardware and software may be used. This approach retains the high performance of a digital hardware implementation, and the flexibility of a software implementation.
- There are many image processing functions which may be performed by the digital image processing unit 528.
- the image may be digitally filtered to enhance edges and suppress video noise.
- the image may be color corrected, and adjusted for brightness and contrast. Special effects and image filters may be applied. Such techniques are well known in the digital video equipment industry.
- the image is ready for printing.
- the image data is read from the digital frame store 529 and digitally halftoned by the vector error diffusion unit 504.
- a vector error diffusion algorithm is used to achieve a high image quality. This operates by selecting the closest printable color in three dimensional color space to the desired Color. The difference between the desired Color and this printable color is determined. This difference is then diffused to neighboring pixels.
- the vector error diffusion unit 504 accepts a raster ordered continuous tone input image and generates a bi-level output with 4 bits per pixel (one bit for each of cyan, magenta, yellow, and grey). Alternatively, the color components can be independently error diffused, although this provides an image of substantially lower quality. It is also possible to dither the continuous tone image to obtain a bi-level image. In this case, a computer optimized dispersed dot ordered dither is recommended.
- CMYK cyan, magenta, yellow, and black
- image quality can be improved by substituting a 50 percent density neutral grey ink for the black ink. This substitution can be made because the video images to be printed will typically not contain small sized black text therefore a single-ink black is not required.
- grey ink provides a better color distribution of the sixteen available ink combinations in a pixel. This improved color distribution can be used to reduce the visual noise resulting from the halftoning process.
- This data is then processed by the data phasing and fault tolerance system 506.
- This unit provides the appropriate delays to synchronize the print data with the offset positions of the nozzle of the printing head. It also provides alternate data paths for fault tolerance, to compensate for blocked nozzles, faulty nozzles or faulty circuits in the print head.
- the monolithic printing head 50 prints the image 60 composed of a multitude of ink drops onto a recording medium 51.
- This medium will typically be paper, but can also be overhead transparency film, cloth, or most other substantially flat surfaces which will accept ink drops.
- the bi-level image processed by the data phasing and fault tolerance circuit 506 provides the pixel data in the correct sequence to the data shift registers 56. Data sequencing is required to compensate for the nozzle arrangement and the movement of the paper.
- the data When the data has been loaded into the shift registers, it is presented in parallel to the heater driver circuits 57. At the correct time, these driver circuits will electronically connect the corresponding heaters 58 with the voltage pulse generated by the pulse shaper circuit 61 and the voltage regulator 62.
- the heaters 58 heat the tip of the nozzles 59, reducing the attraction of the ink to the nozzle surface material. Ink drops 60 escape from the nozzles in a pattern which corresponds to the digital impulses which have been applied to the heater driver circuits.
- the pressure of the ink in the nozzle is important and the pressure in the ink reservoir 64 is regulated by the pressure regulator 63.
- the ink drops 60 fall under the influence of gravity or another field type towards the paper 51.
- the paper is continually moved relative to the print head by the paper transport system 65. As the print head is the full width of the paper used, it is only necessary to move the paper in one direction, and the print head can remain fixed.
- the paper may be supplied as pre-cut sheets, in which case the paper transport mechanism must acquire and transport the sheets individually past the printing head.
- the paper may be provided in rolls. In this case, an automatic paper cutting blade is required.
- control microcomputers 511 which also provide the user interface of the system.
- Example product specifications the specifications of one possible configuration of a PhotoCD player with integrated color printer based on LIFT technology.
- the table "LIFT head type Photo-6-800" is a summary of some characteristics of an example full color monolithic printing head capable of printing a photograph size image at 600 dpi in one second.
- Figure 6 shows a schematic process diagram of a PhotoCD player incorporating a color printer using a printing head.
- the blocks in this diagram represent discrete functions, irrespective of their implementations. Some of the blocks are electronic hardware, some are computer software, some are
- electromechanical units and some are mechanical units. Some of the blocks are subsystems, which may include electronic hardware, software, mechanics, and optics.
- a major unit in the system is the main processor 590.
- This is a microprocessor, and may be any of a wide variety of microprocessors from several different manufacturers.
- the main processor 590 executes computer programs such as image decompression and digital halftoning. It also executes a program providing the user interface to the system.
- the television or monitor 594 is a standard video display unit This is used for viewing the digitally stored photographs prior to printing them. This unit would typically not be supplied with the PhotoCD player, but instead would be supplied by the user.
- a CD-ROM drive 592 is used to access data stored on a PhotoCD encoded digital compact disk.
- the data stored on the disk is primarily in the form of digitally encoded images. For each image, several image sizes are stored. Low resolution index images are stored to allow rapid selection of an image to view.
- Television resolution images 596 are also stored. These are representations of the photographs stored at sufficient resolution to obtain a high quality image on a television set When images are to be viewed on a television set, the image data is read from the PhotoCD using the CD-ROM drive 592.
- This image data is stored in a video frame store 598, consisting of semiconductor memory, timing circuits, data paths, and address generators.
- High resolution images 597 are also stored on the PhotoCD. These are stored in digitally compressed form to reduce the time required to access an image, and to increase the number of images that may be stored on a single PhotoCD disc. These images must be decompressed by an image
- the image decompression unit 595 before being viewed or printed.
- the image decompression unit 595 may be implemented either as software running on the main processor 580, or as an ASIC or other digital hardware implementation.
- a print resolution digital image 597 of the photograph is read from the PhotoCD.
- This data is decompressed by the image decompression unit 595, and digitally halftoned by the digital halftoning unit 515.
- the data is then stored in the bi-level image memory 505.
- the image data is not stored directly after the decompression process. Instead, decompression and digital halftoning occur simultaneously, or in an interleaved manner using a small memory buffer.
- the digital halftoning unit 515 can implement a vector error diffusion algorithm. This operates by selecting the closest printable color in three dimensional color space to the desired Color. The difference between the desired Color and this printable color is determined. This difference is then diffused to neighboring pixels.
- the digital halftoning unit 515 accepts a raster ordered continuous tone (typically 24 bit per pixel) input image and generates a bi- level output with 4 bits per pixel (one bit for each of Cyan, Magenta, Yellow, and black). This is then stored in the bi-level image memory 505.
- the Bi-level image memory 505 is read in real-time. This data is then processed by the data phasing and fault tolerance system 506.
- the various subsystems are coordinated by the main processor 580, or by one or more slave microcontrollers.
- Figure 7(a) shows a top view of video printer, showing the control buttons 901 and the top edge of the paper and ink cartridge 910.
- Figure 7(b) shows the same printer from side view.
- the paper and ink cartridge 910 is inserted into the printer so the paper is in contact with the paper pick-up roller 912.
- a pre-cut sheet of paper is picked up from the paper and ink cartridge 910 by the paper pick-up roller 912 and moved to the paper transport rollers 65. It is then passed beneath the printing head 50, which prints an image derived from the captured video frame.
- the printed sheet 51 is ejected from the front of the device.
- the video capture, image processing, print-head control, and other circuitry is contained on a circuit board 900.
- the user controls the device by pressing control buttons 901.
- Figure 8 shows a perspective view of the printer, showing the control buttons 901 and the top edge of the paper and ink cartridge 910.
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Abstract
Priority Applications (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/750,606 US5859652A (en) | 1995-04-12 | 1996-04-10 | Color video printer and a photo CD system with integrated printer |
EP96912656A EP0765226A1 (fr) | 1995-04-12 | 1996-04-10 | Imprimante video en couleurs et systeme cd photographique a imprimante integree |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AUPN2296 | 1995-04-12 | ||
AUPN2296A AUPN229695A0 (en) | 1995-04-12 | 1995-04-12 | A color video printer using a lift printing system |
AUPN2293 | 1995-04-12 | ||
AUPN2293A AUPN229395A0 (en) | 1995-04-12 | 1995-04-12 | A photocd system with integrated printer |
Publications (1)
Publication Number | Publication Date |
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WO1996032265A1 true WO1996032265A1 (fr) | 1996-10-17 |
Family
ID=25644902
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1996/004907 WO1996032265A1 (fr) | 1995-04-12 | 1996-04-10 | Imprimante video en couleurs et systeme cd photographique a imprimante integree |
Country Status (2)
Country | Link |
---|---|
EP (1) | EP0765226A1 (fr) |
WO (1) | WO1996032265A1 (fr) |
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