Printing method for reducing stitch error between overlapping jetting modules

Abstract

A method of printing is described for a page-width printer including a line head having a plurality of jetting modules that are staggered in a page-width direction. In a set up procedure, a test pattern is printed using the nozzles of adjacent jetting modules, and the pattern is analyzed to detect a stitch error in the overlap regions. The results of this analysis is used to calculate a set of correction values to be applied to print data subsequently sent to nozzles of the adjacent jetting modules to make a correction for the stitch error. During a subsequent production run, the print data sent to the nozzles of the adjacent jetting modules is analyzed to sense an image content attribute, such as gray or density level, of the print data. These results of the analysis of the print data is then used to calculate a dynamic adjustment that is used to adjust the set of correction values calculated during the set up procedure. The line head is then used to print the corrected print data by applying the set of adjusted correction values to production print data subsequently sent to the jetting modules.

Description

FIELD OF THE INVENTIONThe field of the invention relates to page-width printing systems using a line head including a plurality of jetting modules that are staggered in the page-width direction, and more particularly to methods and algorithms for joining the data from the jetting modules in the page-width direction.BACKGROUND OF THE INVENTIONStitching refers to the alignment of the print from multiple jetting modules for the purpose of creating the appearance of a single page-width line head. For example, as shown in FIG. 1, seven jetting modules 2—each three inches in length—can be stitched together at junctures 2a to form a twenty-one inch page-width line head 4. The page-width image data is processed and segmented into separate segments for each jetting module 2, and then a segment is sent—with an appropriate module-to-module delay to account for the staggered separation of the modules—to the print nozzles 6 of each jetting module for printing.However, though it may be anticipate...

AI Technical Summary

Benefits of technology

The present invention is about a method of printing using a line head with multiple jetting modules that are staggered in a page-width direction. The method includes a setup or calibration procedure where test pattern print data is applied to the line head for printing a test pattern on a print media, and the test pattern is analyzed to detect stitch errors. Using the results of the analysis, a set of correction values is calculated and applied to production print data subsequently sent to the jetting modules to make a correction for the stitch error. The invention addresses the problem that corrections for nozzle alignments are not independent of image conditions and suggests making the correction amount dynamic, based on attributes of the image data, such as the gray level or density. By sensing the image data and using it to calculate a dynamic adjustment, the invention achieves a more uniform correction throughout the tone scale of the image being printed.

Problems solved by technology

The applicant has observed that the correction amount obtained during a set-up procedure may not be suitable for all image content in a page-width printer, despite the same degree of misalignment of the jetting modules.

In particular, the applicant has observed that the correction amount obtained during a set-up procedure may not be suitable for all density levels in the image.

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