U.S. patent application number 13/764439 was filed with the patent office on 2014-08-14 for system and method for adjustment of coverage parameters for different colors in image data.
This patent application is currently assigned to Xerox Corporation. The applicant listed for this patent is XEROX CORPORATION. Invention is credited to Katherine Loj, David Robinson.
Application Number | 20140225953 13/764439 |
Document ID | / |
Family ID | 51297181 |
Filed Date | 2014-08-14 |
United States Patent
Application |
20140225953 |
Kind Code |
A1 |
Robinson; David ; et
al. |
August 14, 2014 |
SYSTEM AND METHOD FOR ADJUSTMENT OF COVERAGE PARAMETERS FOR
DIFFERENT COLORS IN IMAGE DATA
Abstract
A method of operating a printer includes reducing a first
plurality of coverage parameters in a first continuous tone
(contone) pixel by a predetermined amount if a combination of at
least two of the coverage parameters is below a predetermined
threshold and reducing a second plurality of coverage parameters in
a second pixel by a smaller amount if the combination of coverage
parameters in the second pixel is greater than the predetermined
threshold. The method further includes generating half-tone image
data from the first and second pixels and forming printed marks
corresponding to the first and second pixels on an image receiving
surface.
Inventors: |
Robinson; David; (Penfield,
NY) ; Loj; Katherine; (Rochester, NY) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
XEROX CORPORATION |
Norwalk |
CT |
US |
|
|
Assignee: |
Xerox Corporation
Norwalk
CT
|
Family ID: |
51297181 |
Appl. No.: |
13/764439 |
Filed: |
February 11, 2013 |
Current U.S.
Class: |
347/15 |
Current CPC
Class: |
H04N 1/6027 20130101;
H04N 1/52 20130101 |
Class at
Publication: |
347/15 |
International
Class: |
B41J 2/205 20060101
B41J002/205 |
Claims
1. A method of operating a printer comprising: identifying a first
plurality of coverage parameters for a first pixel of continuous
tone (contone) image data, each coverage parameter corresponding to
one color separation in a plurality of color separations; reducing
each of the first plurality of coverage parameters by a first
amount in response to a combination of at least two of the first
plurality of coverage parameters being below a predetermined
threshold; identifying a second plurality of coverage parameters
for a second pixel of the contone image data, each coverage
parameter in the second plurality of coverage parameters
corresponding to one color separation in the plurality of color
separations; reducing each of the second plurality of coverage
parameters by a second amount, the second amount being less than
the first amount, in response to a combination of the at least two
of the second plurality of coverage parameters exceeding the
predetermined threshold; generating half-tone image data
corresponding to the first pixel and the second pixel; and
operating a marking unit with reference to the half-tone image data
to form marks corresponding to the first pixel and the second pixel
on an image receiving surface.
2. The method of claim 1 wherein the second amount of reduction is
zero.
3. The method of claim 1 further comprising: identifying an amount
by which the combination of the at least two coverage parameters in
the second pixel exceeds the predetermined threshold; and
identifying the second amount of reduction for the coverage
parameters of the second pixel with reference to the amount by
which the combination of the at least two coverage parameters
exceeds the predetermined threshold.
4. The method of claim 2, the identification of the second amount
of reduction further comprising: identifying that the second amount
of reduction for the coverage parameters of the second pixel is
zero in response to the at least two coverage parameters in the
pixel having maximum coverage parameter values.
5. The method of claim 3 further comprising: identifying the second
amount of reduction with reference to a relationship between the
amount by which the combination of the at least two coverage
parameters in the second pixel exceeds the predetermined threshold,
the first amount of reduction, and a predetermined minimum amount
of reduction for the coverage parameters.
6. The method of claim 5 wherein the relationship is a linear
function.
7. The method of claim 5 wherein the relationship is a logarithmic
function.
8. The method of claim 1 wherein the first amount of reduction is
20% of each of the coverage parameters in the first pixel.
9. A printer comprising: a marking unit configured to deposit
marking agents having a plurality of colors onto an image receiving
surface; and a controller operatively connected to the marking
unit, the controller being configured to: identify a first
plurality of coverage parameters for a first pixel of continuous
tone (contone) image data, each coverage parameter corresponding to
one color separation in a plurality of color separations; reduce
each of the first plurality of coverage parameters by a first
amount in response to a combination of at least two of the first
plurality of coverage parameters being below a predetermined
threshold; identify a second plurality of coverage parameters for a
second pixel of the contone image data, each coverage parameter in
the second plurality of coverage parameters corresponding to one
color separation in the plurality of color separations; reduce each
of the second plurality of coverage parameters by a second amount,
the second amount being less than the first amount, in response to
a combination of the at least two of the second plurality of
coverage parameters exceeding the predetermined threshold; generate
half-tone image data corresponding to the first pixel and the
second pixel; and operate a marking unit with reference to the
half-tone image data to form marks corresponding to the first pixel
and the second pixel on an image receiving surface.
10. The printer of claim 9 wherein the second amount of reduction
is zero.
11. The printer of claim 9, the controller being further configured
to: identify an amount by which the combination of the at least two
coverage parameters in the second pixel exceeds the predetermined
threshold; and identify the second amount of reduction for the
coverage parameters of the second pixel with reference to the
amount by which the combination of the at least two coverage
parameters exceeds the predetermined threshold.
12. The printer of claim 11, the controller being further
configured to: identify that the second amount of reduction for the
coverage parameters of the second pixel is zero in response to the
at least two coverage parameters in the pixel having maximum
coverage parameter values.
13. The printer of claim 11, the controller being further
configured to: identify the second amount of reduction with
reference to a relationship between the amount by which the
combination of the at least two coverage parameters in the second
pixel exceeds the predetermined threshold, the first amount of
reduction, and a predetermined minimum amount of reduction for the
coverage parameters.
14. The printer of claim 13 wherein the relationship is a linear
function.
15. The printer of claim 13 wherein the relationship is a
logarithmic function.
16. The printer of claim 9 wherein the first amount of reduction is
20% of each of the coverage parameters in the first pixel.
17. A method of operating a printer comprising: identifying a
plurality of coverage parameters for a pixel of continuous tone
(contone) image data, each coverage parameter in the pixel
corresponding to a value in a contone plane for one of a plurality
of color separations; modifying an adjustment value for the
coverage parameters in the pixel in response to at least one of the
identified plurality of coverage parameters for the pixel being
greater than a predetermined threshold; and operating a marking
unit to deposit a plurality of colorants that correspond to the
plurality of color separations onto an image receiving surface with
reference to the pixel in the contone plane and the modified
adjustment value.
18. The method of claim 17 further comprising: identifying a sum of
at least two of the coverage parameters for the pixel; and
modifying the adjustment value in response to the sum of the at
least two coverage parameters exceeding the predetermined
threshold.
19. The method of claim 18 wherein the color separations
corresponding to the at least two coverage parameters are a yellow
color separation and a magenta color separation.
20. The method of claim 18, the modification of the adjustment
value further comprising: identifying a difference between a sum of
the at least two coverage parameters for the pixel and the
predetermined threshold; and modifying the adjustment value to be
between a first adjustment value and a second adjustment value with
reference to the identified difference, the second adjustment value
being greater than the first adjustment value.
Description
TECHNICAL FIELD
[0001] This disclosure relates generally to printers that form
color printed images on an image receiving surface and, more
particularly, to printers that generate half-tone printed images
from continuous tone image data.
BACKGROUND
[0002] Color half-tone printing devices deposit marking agents,
such as ink or toner, having a small number of colors onto an image
receiving surface to form a printed image. The marking agent is
deposited in sufficiently small quantities to enable the human eye
to perceive a large number of potential colors from different
combinations of the marking agents. For example, many printers use
cyan, magenta, yellow, and black (CMYK) marking agents to form
multi-color printed images. For example, in an inkjet printer,
different groups of inkjets eject CMYK inks in predetermined
half-tone drop patterns to form the color images, and in a
xerographic printer the CMYK toners are deposited onto a
photoconductive drum or belt and are subsequently transferred to a
print medium.
[0003] One type of half-tone color printer is a drop on demand
inkjet printer. Drop on demand inkjet technology for producing
printed media has been employed in commercial products such as
printers, plotters, and facsimile machines. Generally, an inkjet
image is formed by selectively ejecting ink drops from a plurality
of inkjets, which are arranged in one or more printheads, onto an
image receiving surface. In a direct inkjet printer, the printheads
eject ink drops directly onto the surface of a print medium such as
a paper sheet or a continuous paper web. In an indirect inkjet
printer, the printheads eject ink drops onto the surface of an
intermediate image receiving member such as a rotating imaging drum
or belt. During printing, the printheads and the image receiving
surface move relative to one other and the inkjets eject ink drops
at appropriate times to form an ink image on the image receiving
surface. A controller in the printer generates electrical signals,
also known as firing signals, at predetermined times to activate
individual inkjets in the printer. The ink ejected from the inkjets
can be liquid ink, such as aqueous, solvent, oil based, UV curable
ink or the like, which is stored in containers installed in the
printer. Alternatively, some inkjet printers use phase change inks
that are loaded in a solid form and delivered to a melting device.
The melting device heats and melts the solid phase change ink to a
liquid form that is supplied to a printhead for printing as liquid
drops onto the image receiving surface.
[0004] During the operational life of these printers, inkjets in
one or more printheads may become unable to eject ink or to eject
ink drops of an appropriate mass in response to a firing signal.
These inkjets are described as defective or inoperable inkjets in
this document. When an inkjet becomes inoperable, any printed image
that requires the use of the inoperable inkjet is formed with an
image defect. In printer embodiments where an image receiving
surface, such as a sheet or elongated roll of paper, moves past an
array of printheads in a print zone, the image defect is often
visible as a narrow unprinted line or "light streak" that extends
through the printed image. The light streak appears in locations of
the image where the inoperable inkjet would have ejected ink drops
if the inoperable inkjet were functioning correctly.
[0005] Existing compensation methods enable a printer to form
printed images that reduce or eliminate the visible impact of
inoperable inkjets on the printed images. For example, some
printers operate in a default mode where the relative coverage of
the printed ink that forms printed images is set to a fraction of
the maximum coverage that the printer is capable of producing. For
example, a printer receives image data corresponding to a printed
image and reduces the intensity of the image data by 20% to form
the printed image using an 80% intensity. During operation the
printer increases the intensity level for portions of the printed
image that are located near an inoperable inkjet when an inoperable
inkjet is detected. The increased coverage of ink around the light
streak corresponding to the inoperable inkjet and the spreading of
the ink on the printed paper reduces the perceptibility of the
light streak. The reduced ink coverage in the default print mode
provides a margin for the printer to increase the ink coverage in
selected regions of the printed image to compensate for one or more
inoperable inkjets.
[0006] One drawback to printing images with a reduced intensity
level is that the printed quality of some colors is negatively
impacted due to the reduced coverage of ink in the printed image.
For example, many color printers form images using a small number
of ink colors, such as CMYK inks. Different combinations of the ink
colors that are printed as separate drops in close proximity to
each other or that merge together in the printed image form a wide
range of visible colors to the human eye. To the human eye,
however, the reduced intensity of some colors in the printing
process results in a much more perceptible impact to the quality of
the printed image for some colors in comparison to other colors.
For example, in a CMYK printer, the modified printing process
affects the image quality of the color red to a greater degree than
many other printed colors. In some instances, different shades of
red appear to be orange due to the reduction in the intensity of
the printed image. Thus, the impact on the quality of the printed
images is greatly affected by the color content of the images,
which can lead to reduced image quality. Consequently, improvements
to the process for printing images that improve the quality of the
color reproduction in the printed images would be beneficial.
SUMMARY
[0007] In one embodiment, a method of operating a printer has been
developed. The method includes identifying a first plurality of
coverage parameters for a first pixel of continuous tone (contone)
image data, each coverage parameter corresponding to one color
separation in a plurality of color separations, reducing each of
the first plurality of coverage parameters by a first amount in
response to a combination of at least two of the first plurality of
coverage parameters being below a predetermined threshold,
identifying a second plurality of coverage parameters for a second
pixel of the contone image data, each coverage parameter in the
second plurality of coverage parameters corresponding to one color
separation in the plurality of color separations, reducing each of
the second plurality of coverage parameters by a second amount, the
second amount being less than the first amount, in response to a
combination of the at least two of the second plurality of coverage
parameters exceeding the predetermined threshold, generating
half-tone image data corresponding to the first pixel and the
second pixel, and operating a marking unit with reference to the
half-tone image data to form marks corresponding to the first pixel
and the second pixel on an image receiving surface.
[0008] In another embodiment, a printer that forms printed images
with varying color intensity levels has been developed. The printer
includes a marking unit configured to deposit marking agents having
a plurality of colors onto an image receiving surface and a
controller operatively connected to the marking unit. The
controller is configured to identify a first plurality of coverage
parameters for a first pixel of continuous tone (contone) image
data, each coverage parameter corresponding to one color separation
in a plurality of color separations, reduce each of the first
plurality of coverage parameters by a first amount in response to a
combination of at least two of the first plurality of coverage
parameters being below a predetermined threshold, identify a second
plurality of coverage parameters for a second pixel of the contone
image data, each coverage parameter in the second plurality of
coverage parameters corresponding to one color separation in the
plurality of color separations, reduce each of the second plurality
of coverage parameters by a second amount, the second amount being
less than the first amount, in response to a combination of the at
least two of the second plurality of coverage parameters exceeding
the predetermined threshold, generate half-tone image data
corresponding to the first pixel and the second pixel, and operate
a marking unit with reference to the half-tone image data to form
marks corresponding to the first pixel and the second pixel on an
image receiving surface.
[0009] In another embodiment, a method of operating a printer has
been developed. The method includes identifying a plurality of
coverage parameters for a pixel of continuous tone (contone) image
data, each coverage parameter in the pixel corresponding to a value
in a contone plane for one of a plurality of color separations,
modifying an adjustment value for the coverage parameters in the
pixel in response to at least one of the identified plurality of
coverage parameters for the pixel being greater than a
predetermined threshold, and operating a marking unit to deposit a
plurality of colorants that correspond to the plurality of color
separations onto an image receiving surface with reference to the
pixel in the contone plane and the modified adjustment value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] The foregoing aspects and other features of a printer that
modifies a printing process selectively for different colors in a
printed image are explained in the following description, taken in
connection with the accompanying drawings.
[0011] FIG. 1 is a block diagram of a process for identifying
coverage parameters in pixels of continuous tone image data to
modify contone pixels for selected colors differently during a
printing operation.
[0012] FIG. 2 is a graph depicting adjustment to coverage
parameters in contone pixels based on identified coverage
parameters for two or more color separations in the contone
pixel.
[0013] FIG. 3 is a diagram of a prior art color range corresponding
to a range of coverage parameter values in a pixel.
[0014] FIG. 4 is a schematic diagram of a prior art inkjet
printer.
DETAILED DESCRIPTION
[0015] For a general understanding of the environment for the
system and method disclosed herein as well as the details for the
system and method, reference is made to the drawings. In the
drawings, like reference numerals have been used throughout to
designate like elements. As used herein, the word "printer"
encompasses any apparatus that produces images with colorants on
media, such as digital copiers, bookmaking machines, facsimile
machines, multi-function machines, etc.
[0016] As used herein, the term "inoperable inkjet" refers to a
malfunctioning inkjet in a printer that does not eject ink drops,
ejects ink drops only on an intermittent basis, or ejects ink drops
onto an incorrect location of an image receiving member when the
inkjet receives an electrical firing signal. A typical inkjet
printer includes a plurality of inkjets in one or more printheads,
and operational inkjets that are located near the inoperable inkjet
can compensate for the inoperable inkjet to preserve the quality of
printed images when an inkjet becomes inoperable.
[0017] As used herein, the term "pixel" refers to data that
corresponds to an amount of colored ink at a location in a
two-dimensional grid for an ink image to be produced in a print
job. A printed image is represented by an arrangement of pixels
with different colors at different locations in the image. The term
"contone pixel" refers to a pixel of image data that includes one
or more coverage parameter values that correspond to an intensity
of a pixel in a color separation for an image. In one embodiment, a
pixel includes cyan, magenta, yellow, and black color (CMYK)
separations and each contone pixel includes a numeric coverage
parameter for each of the CMYK separations.
[0018] As used herein, the term "continuous tone" or "contone"
refers to a range of colors that can be represented by a single
contone pixel in the image data. The overall color of a contone
pixel is formed from the colors of the pixels in each color
separation at the same position as the contone pixel that form the
contone pixel. In a theoretical contone plane, the colors in the
plane change continuously over an infinite number of intermediate
color levels between different colors. In a digital representation
of image data for a contone pixel, the different colors in the
plane are represented by discrete digital values, and the number of
discrete digital values is large enough to produce a range of color
levels that appear to be continuous to the human eye.
[0019] The overall color of the contone pixel is typically defined
in a three or four dimensional color-space. Each color separation
includes a contone parameter that represents different intensity
levels of the individual color separation, such as the CMYK
separations. A combination of intensity values for each of the
color separations produces the visible color of the contone
pixel.
[0020] As depicted in FIG. 3, a graph 302 depicts a range of color
intensities for a single color separation from a "pure"
representation of the selected color with maximum intensity that
gradually decreases to zero intensity where the color is not
present. In FIG. 3, the edge 304 depicts a pure hue of a color. For
example, in a CMYK printer, each of the cyan, magenta, yellow, and
black inks represent pure hues of the respective CMYK color
separations. The color gradually lightens from the edge 304 toward
the edge 308 as the intensity of the coverage parameter decreases
and the white background becomes more visible. Some printer
embodiments generate numeric encodings of the color intensity
values in the graph 302 using 8 bits of binary data. In an 8-bit
numeric representation of the coverage parameter intensity, a
numeric coverage parameter value of 255 for a color separation in a
pixel corresponds to the maximum intensity of the color at the edge
304, while a numeric coverage parameter of 0 corresponds to the
edge 308 where the color separation reaches zero intensity. The
contone pixel includes coverage parameter values that correspond to
intensity values for each of the CMYK color separations.
[0021] As used herein, the terms "half-tone pixel" and "binary
pixel" refer to a pixel in a single color separation, such as one
of the CMYK separations, which is either activated or deactivated.
An activated half-tone pixel corresponds to a location where the
printer deposits a marking agent, such as ink or toner, onto an
image receiving surface, while a deactivated half-tone pixel
corresponds to a location where the printer does deposit the
marking agent. In a CMYK printer, four sets of half-tone binary
image data for each of the CMYK color separations are used to
control the operation of a marking unit to form printed images. As
described below, the printer generates half-tone pixels using, for
example, a tone reproduction curve (TRC) to map contone coverage
parameters into half-tone pixels. Half-toning processes including
various forms of dithering and thresholding are used to convert
contone pixels into binary image data that are used to control the
operation of a marking unit to form the printed image. As used in
this document, a "marking unit" refers to a device that is operated
with reference to half-tone data to apply colorant to a surface to
form an image.
[0022] In a CMYK printer, colors in images are formed using
combinations of one or more of the cyan, magenta, yellow, and black
inks in a half-tone image pattern. In the digital image data, each
contone pixel includes a set of values corresponding to locations
in the contone planes for each of the CMYK color separations. A
digital controller in the printer or associated with the printer
converts the contone image data for each pixel into two-dimensional
arrangements of half-tone binary pixels that each correspond to a
single color separation in a printed page. Each of the half-tone
binary image is a two-dimensional array of half-tone pixels that
correspond to locations on the printed page where the printer
either ejects an ink drop or does not eject an ink drop to form the
printed image. In a CMYK color printer, the half-tone pixels for
each of the CMYK color separations control the operation of inkjets
for each of the CMYK ink colors to form color images. The printer
superimposes the half-tone image pixels for each of the CMYK color
separations on a single printed page where the ink drops for the
different colors are positioned close to one another on the printed
page. To the human eye, the different combinations of the CMYK inks
form a large range of perceptible colors on the printed page.
[0023] As described above, digital contone image data include
parameters that describe a wide range of colors for an individual
contone pixel in digital image data. In a half-tone printed image,
however, the combinations of CMYK ink drops in a small region that
corresponds to the size of the contone pixel are incapable of
producing many of the colors that can be represented in each
contone pixel. For example, many printer embodiments are configured
to either print or not print a single ink drop of the CMYK colors
onto a region of the image receiving surface that corresponds to
the pixel. In a printer embodiment with four ink colors, and a
white image receiving surface, such as paper, there are 2.sup.4
(16) potential combinations of ink drops on the paper, and the
option to refrain from printing any ink drops to leave the paper
blank. The half-toning process converts a single contone pixel into
larger arrays of binary image data corresponding to each of the
color separations in the contone pixel, such as the CMYK
separations. The half-tone process activates some or all of the
binary pixels in the arrays based on the coverage parameter value
of the color separation to form the printed color with a varying
level of perceived intensity even though each pixel of half-tone
image data only represents a binary on/off value. As described
below, the printer is configured to adjust the intensity of contone
coverage parameters for selected colors to enable accurate
reproduction of the selected colors when the half-tone image is
printed.
[0024] FIG. 4 depicts a prior-art inkjet printer 5. For the
purposes of this document, an inkjet printer employs one or more
inkjet printheads to eject drops of ink into an image receiving
member, such as paper, another print medium, or an indirect member
such as a rotating image drum or belt. The printer 5 is configured
to print ink images with a "phase-change ink," by which is meant an
ink that is substantially solid at room temperature and that
transitions to a liquid state when heated to a phase change ink
melting temperature for jetting onto the imaging receiving member
surface. The phase change ink melting temperature is any
temperature that is capable of melting solid phase change ink into
liquid or molten form. In one embodiment, the phase change ink
melting temperature is approximately 70.degree. C. to 140.degree.
C. In alternative embodiments, the ink utilized in the printer
comprises UV curable gel ink. Gel inks are also heated before being
ejected by the inkjet ejectors of the printhead. As used herein,
liquid ink refers to melted solid ink, heated gel ink, or other
known forms of ink, such as aqueous inks, ink emulsions, ink
suspensions, ink solutions, or the like.
[0025] The printer 5 includes a controller 50 to process the image
data before generating and delivering the firing signals to the
inkjet ejectors to eject colorants and form an image. Colorants can
be ink, or any suitable substance that includes one or more dyes or
pigments, which is applied to the selected media. The colorant can
be black, or any other desired color, and some printer
configurations apply a plurality of distinct colorants to the
media. The media includes any of a variety of substrates, including
plain paper, coated paper, glossy paper, or transparencies, among
others, and the media can be available in sheets, rolls, or other
physical formats.
[0026] The printer 5 is an example of a direct-to-web,
continuous-media, phase-change inkjet printer that includes a media
supply and handling system configured to supply a long (i.e.,
substantially continuous) web of media 14 of "substrate" (paper,
plastic, or other printable material) from a media source, such as
spool of media 10 mounted on a web roller 8. The media web 14
includes a large number (e.g. thousands or tens of thousands) of
individual pages that are separated into individual sheets with
commercially available finishing devices after completion of the
printing process. Some webs include perforations that are formed
between pages in the web to promote efficient separation of the
printed pages. For simplex printing, the printer 5 passes the media
web 14 through a media conditioner 16, print zone 20, and rewind
unit 90 once.
[0027] The media web 14 is unwound from the source 10 as needed and
a variety of motors, not shown, rotate one or more rollers 12 and
26 to propel the media web 14. The media conditioner includes
rollers 12 and a pre-heater 18. The rollers 12 and 26 control the
tension of the unwinding media as the media moves along a path
through the printer. In alternative embodiments, the printer
transports a cut sheet media through the print zone in which case
the media supply and handling system includes any suitable device
or structure to enable the transport of cut media sheets along a
desired path through the printer. The pre-heater 18 brings the web
to an initial predetermined temperature that is selected for
desired image characteristics corresponding to the type of media
being printed as well as the type, colors, and number of inks being
used. The pre-heater 18 can use contact, radiant, conductive, or
convective heat to bring the media to a target preheat temperature,
which in one practical embodiment, is in a range of about
30.degree. C. to about 70.degree. C.
[0028] The media is transported through a print zone 20 that
includes a series of printhead units 21A, 21B, 21C, and 21D, each
printhead unit effectively extends across the width of the media
and is able to eject ink directly (i.e., without use of an
intermediate or offset member) onto the moving media. In printer 5,
each of the printheads ejects a single color of ink, one for each
of the colors typically used in color printing, namely the CMYK
colors. The printhead units 21A-21D form a marking unit in the
print zone of the printer 5 that deposits the CMYK ink drops onto
the media web 14 to form half-tone color printed images. The
controller 50 receives velocity data from encoders mounted
proximately to rollers positioned on either side of the portion of
the path opposite the four printheads to calculate the linear
velocity and position of the web as the web moves past the
printheads. The controller 50 uses these data to generate firing
signals for actuating the inkjet ejectors in the printheads to
enable the printheads to eject four colors of ink with appropriate
timing and accuracy for registration of the differently colored
patterns to form color images on the media. The inkjet ejectors
actuated by the firing signals correspond to digital data processed
by the controller 50. The digital data for the images to be printed
can be transmitted to the printer, generated by a scanner (not
shown) that is a component of the printer, or otherwise generated
and delivered to the printer. In various configurations, a
printhead unit for each primary color includes one or more
printheads; multiple printheads in a single printhead unit are
formed into a single row or multiple row array; printheads of a
multiple row array are staggered; a printhead prints more than one
color; or the printheads or portions thereof are mounted movably in
a direction transverse to the process direction P for printing
operations, such as for spot-color applications and the like.
[0029] Associated with each printhead unit is a backing member
24A-24D, typically in the form of a bar or roller, which is
arranged substantially opposite the printhead on the back side of
the media. Each backing member positions the media at a
predetermined distance from the printhead opposite the backing
member. The backing members 24A-24D are optionally configured to
emit thermal energy to heat the media to a predetermined
temperature, which is in a range of about 40.degree. C. to about
60.degree. C. in printer 5. The various backer members can be
controlled individually or collectively. The pre-heater 18, the
printheads, backing members 24A-24D (if heated), as well as the
surrounding air combine to maintain the media along the portion of
the path opposite the print zone 20 in a predetermined temperature
range of about 40.degree. C. to 70.degree. C.
[0030] As the partially-imaged media web 14 moves to receive inks
of various colors from the printheads of the print zone 20, the
printer 5 maintains the temperature of the media web within a given
range. The printheads in the printhead units 21A-21D eject ink at a
temperature typically significantly higher than the temperature of
the media web 14. Consequently, the ink heats the media, and
temperature control devices can maintain the media web temperature
within a predetermined range. For example, the air temperature and
air flow rate behind and in front of the media web 14 impacts the
media temperature. Accordingly, air blowers or fans can be utilized
to facilitate control of the media temperature. Thus, the printer 5
maintains the temperature of the media web 14 within an appropriate
range for the jetting of all inks from the printheads of the print
zone 20. Temperature sensors (not shown) can be positioned along
this portion of the media path to enable regulation of the media
temperature.
[0031] Following the print zone 20 along the media path are one or
more "mid-heaters" 30. A mid-heater 30 can use contact, radiant,
conductive, and/or convective heat to control a temperature of the
media. The mid-heater 30 brings the ink placed on the media to a
temperature suitable for desired properties when the ink on the
media is sent through the spreader 40. In one embodiment, a useful
range for a target temperature for the mid-heater is about
35.degree. C. to about 80.degree. C. The mid-heater 30 has the
effect of equalizing the ink and substrate temperatures to within
about 15.degree. C. of each other. Lower ink temperature gives less
line spread while higher ink temperature causes show-through
(visibility of the image from the other side of the print). The
mid-heater 30 adjusts substrate and ink temperatures to 0.degree.
C. to 20.degree. C. above the temperature of the spreader.
[0032] Following the mid-heaters 30, a fixing assembly 40 applies
heat and/or pressure to the media to fix the images to the media.
The fixing assembly includes any suitable device or apparatus for
fixing images to the media including heated or unheated pressure
rollers, radiant heaters, heat lamps, and the like. In the
embodiment of the FIG. 4, the fixing assembly includes a "spreader"
40, which applies a predetermined pressure, and in some
implementations, heat, to the media. The function of the spreader
40 is to flatten the individual ink droplets, strings of ink
droplets, or lines of ink on web 14 and to flatten the ink with
pressure and, in some systems, heat. The spreader flattens the ink
drops to fill spaces between adjacent drops and form uniform images
on the media web 14. In addition to spreading the ink, the spreader
40 improves fixation of the ink image to the media web 14 by
increasing ink layer cohesion and/or increasing the ink-web
adhesion. The spreader 40 includes rollers, such as image-side
roller 42 and pressure roller 44, to apply heat and pressure to the
media. Either roller can include heat elements, such as heating
elements 46, to bring the web 14 to a temperature in a range from
about 35.degree. C. to about 80.degree. C. In alternative
embodiments, the fixing assembly spreads the ink using non-contact
heating (without pressure) of the media after the print zone 20.
Such a non-contact fixing assembly can use any suitable type of
heater to heat the media to a desired temperature, such as a
radiant heater, UV heating lamps, and the like.
[0033] In one practical embodiment, the roller temperature in
spreader 40 is maintained at an optimum temperature that depends on
the properties of the ink, such as 55.degree. C. Generally, a lower
roller temperature gives less line spread while a higher
temperature produces imperfections in the gloss of the ink image.
Roller temperatures that are too high may cause ink to offset to
the roller. In one practical embodiment, the nip pressure is set in
a range of about 500 to about 2000 psi/side. Lower nip pressure
produces less line spread while higher pressure may reduce pressure
roller life.
[0034] The spreader 40 can include a cleaning/oiling station 48
associated with image-side roller 42. The station 48 cleans and/or
applies a layer of some release agent or other material to the
roller surface. The release agent material can be an amino silicone
oil having viscosity of about 10-200 centipoises. A small amount of
oil transfers from the station to the media web 14, with the
printer 5 transferring approximately 1-10 mg per A4 sheet-sized
portion of the media web 14. In one embodiment, the mid-heater 30
and spreader 40 are combined into a single unit, with their
respective functions occurring relative to the same portion of
media simultaneously. In another embodiment the media is maintained
at a high temperature as the media exits the print zone 20 to
enable spreading of the ink.
[0035] In printer 5, the controller 50 is operatively connected to
various subsystems and components to regulate and control operation
of the printer 5. The controller 50 is implemented with general or
specialized programmable processors that execute programmed
instructions to operate one or more electronic components to
perform functions or processes. The instructions and data required
to perform the programmed functions are stored in a memory 52 that
is associated with the controller 50. The processors, their
memories, and interface circuitry configure controllers and/or a
print engine to perform printer operations. These components can be
provided on a printed circuit card or provided as a circuit in an
application specific integrated circuit (ASIC). Each of the
circuits can be implemented with a separate processor or multiple
circuits can be implemented on the same processor. Alternatively,
the circuits can be implemented with discrete components or
circuits provided in VLSI circuits. Also, the circuits described
herein can be implemented with a combination of processors, ASICs,
discrete components, or VLSI circuits. In the embodiment of FIG. 4,
the controller 50 receives image data for printed images in a
contone data format and uses the TRC that is stored in the memory
52 to generate the halftone binary image data that are used to
operate the inkjets in the printhead units 21A-21D to control the
ejection of ink drops onto the media web 14.
[0036] The controller 50 is operatively connected to the printheads
in the printhead units 21A-21D. The controller 50 generates
electrical firing signals to operate the individual inkjets in the
printhead units 21A-21D to eject ink drops that form printed images
on the media web 14. The activated inkjets receive firing signals
and eject ink drops at various times during the printing process.
The deactivated inkjets do not receive the firing signals, and
consequently do not eject ink drops during the printing
process.
[0037] The printer 5 includes an optical sensor 54 that is
configured to generate image data corresponding to the media web 14
and a backer roller 56. The optical sensor is configured to detect,
for example, the presence, reflectance values, and/or location of
ink drops jetted onto the receiving member by the inkjets of the
printhead assembly. The optical sensor 54 includes an array of
optical detectors mounted to a bar or other longitudinal structure
that extends across the width of an imaging area on the image
receiving member. In one embodiment in which the imaging area is
approximately twenty inches wide in the cross-process direction and
the printheads print at a resolution of 600 dpi in the
cross-process direction, over 12,000 optical detectors are arrayed
in a single row along the bar to generate a single scanline of
image data corresponding to a line across the image receiving
member. The optical detectors are configured in association in one
or more light sources that direct light towards the surface of the
image receiving member. The optical detectors receive the light
generated by the light sources after the light is reflected from
the image receiving member. The magnitude of the electrical signal
generated by an optical detector in response to light being
reflected by the bare surface of the media web 14, markings formed
on the media web 14, and portions of a backer roller support member
56 that are exposed to the optical sensor 54. The magnitudes of the
electrical signals generated by the optical detectors are converted
to digital values by an appropriate analog/digital converter.
[0038] During operation, the controller 50 receives contone image
data, which typically includes a plurality of image data pixels
with color separations, such as red, green, blue (RGB) or CMYK
separation values, which correspond to contone planes for the color
separations. In one embodiment, each contone pixel includes an
8-bit numeric parameter corresponding to the relative coverage
parameter for each of the color separations in the pixel. The
minimum value (0) indicating zero coverage in the color separation
and the maximum value (255) indicates full coverage of the color at
100% saturation. Intermediate values correspond to different levels
of coverage between zero and full coverage. Since the inkjet
printer 5 ejects ink drops in a half-tone print mode, the
controller 50 maps the coverage parameters in the contone image
data to a predetermined TRC that is stored in the memory 52. The
controller 50 uses the TRC to translate the contone coverage
parameter values into a series of binary pixels that correspond to
locations on the media web 14 where the inkjets in the printhead
units 21A-21D either eject ink drops or do not eject ink drops to
form a half-tone printed image. The TRC is used as part of a
dithering process that enables the printer 5 to reproduce a large
number of perceptible colors using a small number of inks, such as
the CMYK inks. The TRC accounts for the physical properties of the
printed ink drops, including the propensity of the ink drops to
spread on the surface of the media web 14, to enable generation of
half-tone printed images that accurately reproduce the contone
image. The use of TRCs for the conversion of contone image data to
half-tone image data is well known in the art and is not explained
in greater detail herein.
[0039] In some operating modes, such as when an inoperable inkjet
is detected, the controller 50 reduces the contone coverage
parameters for the color separation values in each pixel to re-map
the contone pixels to different locations on the corresponding TRC
for each color separation. For example, if the coverage parameter
for cyan in a contone pixel has a value of 240, the controller 50
reduces the value by a predetermined amount, such as an offset of
-15, to a re-mapped value of 225. The reduced coverage parameter
value of the contone pixel corresponds to a different location on
the TRC.
[0040] As described above, the controller 50 reduces the contone
coverage parameters for most of the contone pixels in the image to
lighten the image in a selected print modes. If the controller 50
identifies an inoperable inkjet, then the controller 50 increases
the coverage parameter values for contone pixels corresponding to
inkjets that are near the inoperable inkjet to compensate for the
inoperable inkjet. Some inoperable inkjet compensation processes
also generate additional halftone pixels for the nearby operational
inkjets to increase the coverage around the inoperable inkjet. The
increased ink coverage in the region surrounding the inoperable
inkjet reduces the visual perceptibility of the light streak.
[0041] During the print modes where the contone image data for
pixels are adjusted so they map to different locations on the TRC,
the reduced coverage parameters can have a disproportionate impact
on the perceived image quality of some colors. For example, in the
CMYK printer 5, different shades of red are reproduced using
combinations of the magenta and yellow inks. The reduction of the
magenta and yellow coverage parameters in the contone image data
can result in the printed color appearing to be orange instead of a
slightly lighter shade of red. Many other colors, however, do not
suffer from the loss in image quality in the reduced coverage print
mode. As described below, the controller 50 is configured to
identify combinations of coverage parameter values in two or more
color separations in the contone image data and modify the
reduction in the coverage parameters to improve the image quality
for selected colors in the printed document.
[0042] While the printer 5 described above is an embodiment of an
inkjet printer, the printing processes described herein are also
suitable for use with other half-tone printer embodiments
including, but not limited to, xerographic printers. For example,
in a xerographic printer the contone image data are adjusted to
lighten the contone pixels that form the image, but the contone
image data for pixels that correspond to the predetermined colors
are either adjusted by a smaller amount or not adjusted to preserve
the image quality of the selected colors in the printed image. A
marking unit in the xerographic printer deposits CYMK toners onto a
photoconductive drum or belt in locations corresponding to the
half-tone pixels in each of the color separations.
[0043] FIG. 1 depicts a process 100 that adjusts the contone image
data for different pixels in contone image data to reduce the
negative impact of the re-mapping selected pixel colors to
different locations on the TRC in the image. In the description
below, a reference to the process 100 performing or doing some
function or action refers to one or more controllers or processors
that are configured with programmed instructions, which are
executed by the controllers or processors to implement the process
performing the function or action or operating one or more
components to perform the function or action. Some embodiments of
process 100 adjust the coverage parameters of each contone pixel in
the image data. In other embodiments, the printer omits contone
pixels that are located near image data corresponding to an
inoperable inkjet to enable compensation for the inoperable inkjet.
Process 100 is described with reference to the printer 5 of FIG. 4
for illustrative purposes.
[0044] Process 100 begins with identification of coverage
parameters for each of the color separations in the contone planes
for a contone pixel in image data (block 104). For example, in some
embodiments each contone pixel of image data includes 8-bit numeric
values in a range of 0 to 255 that correspond to the amount of a
color in each of the color separations used in the printer. In some
embodiments, the contone CMYK data are generated from an image
input that is encoded using a different set of colors, such as red,
green, and blue (RGB) colors, and the controller 50 identifies the
CMYK coverage parameters using a conversion process that is known
to the art. In the CMYK printer 5, the controller 50 receives 32
bits of digital data corresponding to a contone pixel, with the
32-bit value including 8-bit numeric values corresponding to the
amount of cyan, magenta, yellow, and black colors that form the
contone pixel.
[0045] The overall color of the contone pixel is a combination of
the different CMYK colors at different coverage levels. In the
embodiment described above where each color separation has an 8-bit
coverage parameter, a coverage parameter value of 0 indicates that
the color separation is not used to form the pixel color, and a
value of 255 indicates that the maximum intensity of the color
separation is used to form the contone pixel. Intermediate values
indicate that varying levels of the color separation are used to
form the contone pixel. In another embodiment, the numeric values
are expressed as a percentage value between 0% for minimum coverage
and 100% for maximum coverage, and alternative embodiments include
other appropriate numeric scales to express the coverage parameter.
The print medium is white paper in many common configurations,
which results in a white (blank) pixel when all four of the CMYK
color separations have a value of 0. As depicted in FIG. 3, the
numeric value for each color separation corresponds to a location
along the line 316 between white at corner 312 (zero coverage) and
the pure ink color at corner 304 (maximum coverage).
[0046] Referring again to FIG. 1, process 100 identifies if the
coverage parameter values for one or more color separations in the
contone pixel exceed a predetermined threshold that corresponds to
one or more contone pixel colors (block 108). In one embodiment of
process 100, the predetermined thresholds are selected to identify
printed colors that are most susceptible to perceptible image
quality degradation when the image is printed due to the coverage
parameter adjustment process. For example, in some printer
configurations colors with a red-shade suffer a disproportionate
degradation in image quality due to the coverage parameter
adjustment process. The red colors include large magenta and yellow
coverage parameters. In the printer 5, the memory 52 stores one or
more predetermined threshold values for both the magenta and yellow
parameters individually and a sum of the two parameters. For
example, the memory 52 stores a minimum threshold value of 60% for
each of the magenta and yellow parameters and a combined threshold
value of 125% for the sum of the magenta and yellow parameters. The
controller 50 identifies whether the coverage parameters in the
contone pixel for the magenta and yellow color separations both
exceed the individual threshold values of 60% and whether the sum
of the two coverage parameters exceeds the combined threshold of
125%. For example, a pixel with coverage parameters of 85% magenta
and 55% yellow exceeds the total threshold, but does not exceed the
threshold for yellow, while a pixel with coverage parameters of 65%
magenta and 65% yellow exceeds the individual and combined
thresholds for magenta and yellow. In an alternative embodiment,
the controller 50 only uses the combined threshold value to
identify whether the color of the contone pixel corresponds to one
of the predetermined colors, such as red, that receive a modified
coverage parameter adjustment setting. The threshold values can
include thresholds for each color separation and combination of
color separations that are used in the printer.
[0047] While shades of red are provided as an example of colors
that receive a modified coverage parameter adjustment operation,
the printer 5 can be configured to perform a modified coverage
parameter adjustment operation for other colors as well. In one
configuration, the predetermined colors are selected as part of a
print job to adjust the coverage parameter adjustment operation
that is applied to particular colors. For example, if a print job
includes a printed logo with one or more colors that should be
reproduced accurately, then the memory 52 stores threshold values
that correspond to the colors of the logo, which are either
received with the contone pixel data for the print job or are
stored in the memory 52 through a graphical user interface (GUI) or
other control interface with the printer 5.
[0048] If the identified coverage parameters exceed the
predetermined thresholds for the contone pixel (block 108), then
the controller applies a modified coverage parameter adjustment
process to the coverage parameters in the contone pixel (block
112). The modified coverage parameter adjustment process reduces
the coverage parameters in the contone pixel by a smaller amount
than a default adjustment value if the combined coverage parameters
for the selected color separations exceed the predetermined
threshold. In some embodiments, the modification of the coverage
parameter adjustment process corresponds to the degree to which the
combined coverage parameters for the selected color separations in
the contone pixel exceed the predetermined threshold. In some
embodiments, the controller 50 does not reduce the coverage
parameters for a pixel that exceeds the predetermined
threshold.
[0049] FIG. 2 is a graph 200 that depicts one embodiment of a
coverage parameter adjustment modification function. In the graph
200, the region 204 represents pixels with combined coverage
parameters that are below the predetermined threshold. The pixels
in segment 204 that have a combined coverage parameter value below
the threshold or that have at least one color separation pixel with
a coverage parameter that is below the predetermined threshold for
the individual color separation receive the default coverage
parameter adjustment, which is set at 80% in the example of FIG. 2.
In FIG. 2, the coverage parameter adjustment reduces the default
coverage parameters in a contone pixel by 20% for any contone pixel
that does not include combined coverage parameters that exceed the
predetermined threshold for the selected color.
[0050] If the coverage parameters for the contone pixel exceed the
predetermined threshold, then the printer reduces the coverage
parameters for the contone pixel by a smaller amount, and in some
pixels the printer retains the original coverage parameter values
of the contone pixel. In FIG. 2, the line segment 212 depicts the
relative coverage parameter percentage in the contone pixels having
a combined coverage parameter value that exceeds the threshold 208.
In FIG. 2, the percentage density for the coverage parameters in
the contone pixels are reduced by smaller amounts in comparison to
the original density of the contone pixels with the adjusted
coverage parameters increasing linearly in proportion to the amount
that the combined coverage parameters exceed the threshold 208. In
the graph 200, the contone coverage parameter density reaches 100%
for pixels that include a maximum combined coverage parameter value
for each of the color separations at reference 216. For example,
using the example of red colors described above, the coverage
parameter adjustment process does not adjust the contone coverage
parameters for a contone pixel that includes maximum coverage
parameter values for the magenta and yellow color separations. FIG.
2 is an illustrative example of a linear relationship for modifying
the coverage parameter adjustment, but alternative embodiments
include non-linear relationships, such as logarithmic functions. In
another embodiment, a predetermined coverage parameter adjustment
modification is applied to any pixel that exceeds the predetermined
threshold, such as increasing the relative percentage density of
any contone pixels that exceed the threshold to 100% of the
original coverage parameters in the contone pixels or to another
level that is greater than the default coverage parameter
adjustment.
[0051] Referring again to FIG. 1, if the identified coverage
parameters do not exceed the predetermined thresholds for the pixel
(block 108), then the controller applies a default adjustment
process to reduce the coverage parameter values of the pixel by a
predetermined amount (block 116). Using the example provided above,
the controller 50 reduces the value of each coverage parameter by
20%. In another embodiment, the numeric values for each coverage
parameter are reduced by a predetermined amount, such as reducing
each coverage parameter value in a range of 0-255 by 10. In some
embodiments the coverage parameters are not reduced below a minimum
value to prevent the printer from completely deactivating a contone
pixel in the image data.
[0052] Referring again to FIG. 1, process 100 continues for
additional contone pixels in the image data (block 120). Process
100 continues in an iterative manner until the coverage parameters
for each of the contone pixels in the image have been processed.
Once all of the contone image pixels have been processed (block
120), the printer 5 generates half-tone image data for each of the
modified contone pixels (block 124). In the printer 5, the
controller 50 uses the TRC stored in the memory 52 to generate
half-tone pixels in the CMYK color separations using the modified
contone pixels of image data as inputs to the half-tone process.
The controller 50 uses the half-tone image data pixels to control
the operation of the inkjets in the printhead units 21A-21D to form
the printed image corresponding to the contone pixels on the media
web 14 (block 128). As described above, the reduced coverage
parameters in the contone image data result in a reduced density of
printed ink drops reduces the visibility of light streaks from
inoperable inkjets in an inkjet printer. In inkjet and xerographic
printers, the reduced density also reduces marking agent
consumption in selected print modes. The predetermined contone
colors, such as red, are formed with an increased density to
increase the image quality.
[0053] It will be appreciated that various of the above-disclosed
and other features, and functions, or alternatives thereof, may be
desirably combined into many other different systems or
applications. Various presently unforeseen or unanticipated
alternatives, modifications, variations, or improvements therein
may be subsequently made by those skilled in the art, which are
also intended to be encompassed by the following claims.
* * * * *