Inkjet recording apparatus

An inkjet recording apparatus is adapted to form an image on a printing medium 10, and recognize an image forming region as a region of pixels having drop amounts unequal to zero in the image. A drop amount increase/decrease controller 342 executes an increase/decrease process of drop amount at a current pixel as a target of the process, in accordance with an attribute of the current pixel when the current pixel is included in the image forming region. Pixels are made of ink discharged from nozzles arrayed in a scan direction perpendicular to a transfer direction of the recording medium 10. The drop amount increase/decrease controller 342 executes the increase/decrease process of drop amount in a reverse increase/decrease pattern to ink to be discharged from a neighboring nozzle.

TECHNICAL FIELD

The present invention relates to an inkjet recording apparatus for discharging ink onto a printing medium to form images thereon, and particularly, to an inlet recording apparatus adapted for a function to reduce the degradation of image quality due to blocking of nozzles.

BACKGROUND ARTS

There are inkjet recording apparatuses operable as an image forming apparatus for propelling droplets of ink out of nozzles to thereby draw images. Such inkjet recording apparatuses sometimes experience ink droplets being discharged in deviated directions, or in some cases even a failure to discharge ink droplets. Deviated discharge directions make flexed orbits, resulting in deviated shot positions on a printing medium. Such phenomena may be caused by a degraded precision in production of nozzles used for propelling out ink droplets, or by paper dust or such adhering to discharge ends of nozzles. Occurrences of such phenomena may produce white lines in an image forming region on a printing medium, causing the image quality to be degraded.

In particular, white lines produced in the bar code printing, which requires a high precision of printing, may change the width of black bar or separate black bars, causing a reading device such as a scanner to fail in reading a correct bar code.

Against such an issue, there are techniques including detecting nozzles failing to discharge ink, and printing those images which should have been formed by the discharge failing nozzles (Patent Literature 1: Japanese Patent Publication No. 3157880, Patent Literature 2: Japanese Patent Application Laid-Open Publication No. 2-22066, Patent Literature 3: Japanese Patent Publication No. 2989723, Patent Literature 4: Japanese Patent Publication No. 3313819, and Patent Literature 5: Japanese Patent Application Laid-Open Publication No. 4-185462). More specifically, Patent Literatures 1 and 2 have disclosed techniques including detecting nozzles failing to discharge ink, and using nozzles in other ink heads to complement those regions located under the discharge failing nozzles. Patent Literatures 3 and 4 have disclosed techniques including detecting nozzles failing to discharge ink, using other nozzles in the same ink head to complement the regions under the discharge failing nozzles. Patent Literature 5 has disclosed techniques employing a multi-pass system in which ink heads discharge ink, moving perpendicularly to the transfer direction of a printing medium, and repeat a plurality of passes commensurate with the scan width. This technique includes detecting nozzles failing to discharge ink, and complementing the regions under the discharge failing nodes in other passes.

However, the techniques disclosed in Patent Literatures 1 to 5 need detecting all nozzles for problematic ink discharge. This detection needs additional provision of detecting elements such as optical sensors, causing the equipment cost to be increased. In particular, those single pass systems using a line head longer than the width of a printing range require a length of optical sensor array commensurate with the printable width. This requirement invites a wide increase in production cost. Further, those configurations providing an ink head to cover missing dots like Patent Literature 2 have an increased cost for addition of the head. Also those configurations arraying nodes in parallel to the sheet transfer direction like Patent Literature 4 push up the production cost of the head itself.

Some methods use nozzles working for discharge to complement the regions under discharge failing nozzles, assuming a configuration specific to a printing system such as a single pass system or a multi-pass system. Such methods are inapplicable to different printing systems.

More specifically, there are inkjet recording apparatuses categorized into a group of single pass systems or a group of multi-pass systems, as described. Single pass systems employ a line head longer than the width of a printing range, and form all regions to be printed for a printing while a printing medium once passes under the line head. Inkjet recording apparatuses using single pass systems are thus given no more than a single chance to have a recording medium passing under a line head. Therefore, they are unable to employ any system based on a premise of passing printing regions a plurality of times for a printing thereon, affording to make use of different passes for a printing to complement the regions under discharge-failing nozzles.

Likewise, dedicated units for the monochrome printing are in applicable to those methods based on a configuration specific to the color printing, to use nozzles working for discharge to complement the regions under discharge failing nozzles. That is, monochrome printers simply provided with an ink head for a black color are unable to employ any system using a head for a different color for the complementation, as disclosed in Patent Literature 1, for instance.

It is noted that Patent Literature 6 (Japanese Patent Application Laid-Open Publication No. 2006-82528) has disclosed a technique not based on any premise of detecting nozzles for failed discharge. The technique disclosed in Patent Literature 6 employs an n-row by n-column matrix of nozzles (n: two or larger integer) for discharging ink to a single pixel, and uses nozzles working for discharge to complement the regions under discharge failing nozzles.

However, the technique disclosed in Patent Literature 6 must discharge ink from two or more nozzles to form a single pixel. There may be a case needing a specification for the configuration exceeding a required resolution. It therefore is difficult to take this technique as a versatile solution.

SUMMARY OF THE INVENTION

The present invention has been invented in view of the foregoing circumstances. It is an object of the present invention to provide an inkjet recording apparatus adapted to reduce white lines caused by failures in discharge, allowing for a reduced degradation of image quality. The adaptation should be done without the need of detecting nozzles for non-conformity in ink discharge, in free of specific bases premising a printing system such as a single pass system or a multi-pass system, or a color specification such as a monochrome printing or a color printing.

To achieve the object, according to an aspect of the present invention, there is an inkjet recording apparatus adapted to form an image on a printing medium (for instance, a printing medium10inFIG. 3A). The inkjet recording apparatus includes an ink head, a region detector, and a drop amount increase/decrease controller (for instance, a drop amount increase/decrease controller342inFIG. 4). The ink head has nozzles each adapted to change a drop amount of ink discharged therefrom to each of pixels in the image. The region detector is configured to detect an image forming region in the image. The drop amount increase/decrease controller is configured to execute an increase/decrease process of drop amount of ink to increase or decrease a drop amount of ink discharged to a current pixel (for instance, a current pixel410aor410binFIG. 6B). The current pixel is current in the image as a target of the increase/decrease process of drop amount of ink. The increase/decrease process of drop amount of ink is executed in accordance with an attribute of the current pixel when the current pixel is included in the image forming region.

DESCRIPTION OF THE EMBODIMENTS

(An Inkjet Recording Apparatus and the Entire Configuration)

There will be described an embodiment of the present invention with reference to the drawings.FIG. 1illustrates a side view of an image forming route CR1for forming images in an inkjet recording apparatus according to the present embodiment.FIG. 2Aillustrates a bottom view of a head holder500disposed above the route CR1working as a transfer route.FIG. 2Billustrates an enlarged longitudinal sectional view of the head holder500. It is noted that the embodiment to be described is an example of application to a line color printer that employs an inkjet system including a head unit110as an array of ink heads110aprovided with nozzles. The nozzles are each formed to propel out a variable amount of drops (in terms of the number of drops) of a black or color ink, to make a print in a unit of line.

According to the present embodiment, the inkjet recording apparatus includes the image forming route CR1working as a transfer route for printing media, as illustrated inFIG. 1. The image forming route CR1has a platen belt160operable to transfer a printing medium10at a speed determined in accordance with a printing condition. The head unit110is disposed above the image forming route CR1, in opposition to the platen belt160. Ink heads110ain the head unit110are operable to discharge ink of respective colors from their nozzles onto a printing medium10on the platen belt160, to form superimposed images thereon in a unit of line.

More specifically, the image forming route CR1includes the platen belt160being an endless transfer belt, a combination of driver rollers161and driven rollers162as a drive mechanism for the platen belt, etc. The head holder500is disposed above the image forming route CR1to hold the array of ink heads110a.

The platen belt160is driven by the drive rollers161to go around, and receives a printing medium10to carry within a travel range opposing the array of ink heads110a. More specifically, the platen belt160is stretched over paired drive rollers161and driven rollers162, as they are arranged in a direction perpendicular to the transfer direction, and is driven by drive power of the drive rollers161to go around in the transfer direction.

The head holder500is formed as a box member with a head holder side500aat the bottom. The head holder500holds the ink heads110ato fix in positions, accommodating other functional parts as a unit for discharging ink from the ink heads110a. The head holder side500aconstituting a bottom of the head holder500is disposed in position opposing the transfer route, to be parallel thereto. The head holder side500ahas an array of fixing holes500bformed therethrough in shapes identical to horizontal sections of the ink heads110aconstituting the head unit110. The ink heads110aare inserted into the fixing holes500b, with their discharge ends projecting downward from the head holder side500a.

As illustrated inFIG. 2AandFIG. 2B, the array of ink heads110ais composed of four sub-arrays each oriented in a direction (as a main scan direction) perpendicular to the transfer direction (as a by-scan direction), constituting a line of ink heads. In this embodiment, in each sub-array, the ink heads are adapted to discharge an assigned one of four colors of ink being K (black), C (cyan), M (magenta), and Y (yellow). Each sub-array is composed of a pair of linear arrays of ink heads110a. Ink heads110ain either linear array are staggered to ink heads110ain the other linear array to cover a whole width of a printable range.

Further, as illustrated inFIG. 3A, each ink head110ahas an ink discharge header111at the bottom, in which nozzles111aare arrayed in the main scan direction perpendicular to the transfer direction of a printing medium10. Each nozzle111ais adapted to discharge a drop amount predetermined every pixel, to form toned images. More specifically, each ink head110ais made up to propel out amounts of ink in a unit of drop21. As illustrated inFIG. 3B, associated pixels20have their dot gains controlled to change densities of each color, depending on amounts (i.e., numbers) of drops21of ink discharged thereto. The inkjet recording apparatus has a function of increasing and decreasing drop amounts between neighboring pixels to thereby reduce a degradation of image quality.

(Configuration for the Function of Reducing the Degradation of Image Quality)

According to the present embodiment, the inkjet recording apparatus includes an operational processor330operable to control operations of the head unit110and associated drives to implement the function of reducing the degradation of image quality.FIG. 4shows in a block diagram a set of modules associated with the function of reducing the degradation of image quality at the operational processor330according to the present embodiment.

As shown inFIG. 4, the operational processor330includes a job data receiving interface331, an image formation controller340, and a memory350as modules for reducing the degradation of image quality.

The job data receiving interface331serves as a communication interface to receive a series of data on units of print processing, as a job data. It works as a module to transfer print data in the received job data to an increase/decrease controlling region detector341and an image outputting interface343. The communication referred herein may cover LANs such as intra-networks (as intra-fur networks) using e.g. a 10 BASE-T or 100 BASE-TX, and home networks, and local service loops such as infrared communications. The print data in the job data may involve image data as information on drop amounts representative of densities of pixels constituting RGB, CMYK, or gray scale images, and coordinates representative of drop positions.

The memory350may be a memory device or the like for storing and holding therein programs and various data on the processing of images. In the present embodiment, the memory350has a set drop amount increase/decrease control data D1defining increments and decrements of drop amounts associated with pixel positions.

The set of drop amount increase/decrease control data D1is a set of data on increase/decrease representation for dither matrices, as they are re-defined by increase/decrease patterns of drop amounts to read in accordance with coordinates of current pixels. In the present embodiment, drop amount increase/decrease control data D1are defined as a repetition of those patterns illustrated inFIG. 5AandFIG. 5B. The patterns inFIG. 5AandFIG. 5Bare each defined simply as a combination of signs (+) of an increment and signs (−) of a decrement.

The pattern inFIG. 5Ais an example of pattern in which increments (+) and decrements (−) are alternately allocated one by one in both of the main scan direction (as an X direction) and the by-scan direction (as a Y direction). The pattern inFIG. 5Bis an example of pattern in which pairs of increments (+) and pairs of decrements (−) are alternately allocated in the main scan direction. For the by-scan direction, this pattern has increments (+) and decrements (−) alternately allocated one by one. In other words, for the main scan direction (the X direction),FIG. 5Bshows an example of increase/decrease patterns defined in a unit of a set of neighboring two nozzles. Such increase/decrease patterns are used in processes of increasing/decreasing drop amounts in the unit of neighboring nozzle set.

The set of drop amount increase/decrease control data D1is based on to change increments and decrements depending on differences of densities at current pixels, i.e., that of dot gains on a printing medium10. It is noted that drop amount increase/decrease control data may be calculated from coordinates when they have regular increase/decrease patterns. Further, drop amount increase/decrease control data may involve data on increments and decrements defined in terms of drop number, or in terms of a proportion (%) to the whole drop amount of each pixel.

As illustrated inFIG. 5CandFIG. 5D, the set of drop amount increase/decrease control data D1is stored as a set of patterns, such as D11and D12, each defined over an entire image as a repetition of patterns illustrated inFIG. 5AandFIG. 5B.

The set of definition patterns such as D11and D12may be factory-set in accordance with a property of machine type. There may be sets of definition data stored in advance to permit an automatic selection depending on printing conditions such as a property of ink and a paper quality of recording medium. The selection may be manual to accept a user's preference.

The image formation controller340serves as an operational processor adapted to process digital signals dedicated to processing images, and works as a module for performing conversions of image data and the like, as necessary, for a printing to be executed. In the present embodiment, the image formation controller340includes the increase/decrease controlling region detector341, the drop amount increase/decrease controller342, and the image outputting interface343. These modules serve as tools for controlling drives for ink heads of respective colors, to increase and decrease drop amounts.

The increase/decrease controlling region detector341is a module adapted, as illustrated inFIG. 6A, to analyze image data400including information on a density at each pixel in an input image. This module detects a region (of pixels having drop amounts unequal to ‘0’) to be a target region of an increase/decrease process, as an image forming region A1(e.g. a region having drop numbers ‘5’ inFIG. 6AorFIG. 6B). That is, the region detector341analyzes data400of an input image for each pixel, to calculate a drop amount for the pixel. Then, it detects a region of pixels each having a drop amount unequal to ‘0’, as an image forming region A1.

For instance, as illustrated inFIG. 6B, when a pixel410ais selected as a current pixel, surrounding pixels411aneighboring the current pixel410aat eight directions include pixels having a drop amount equal to ‘0’. Then, the edge detector344recognizes “an edge region” as an attribute of the current pixel410a, and determines that the current pixel410adoes not constitute any target of an increase/decrease control of drop amount. On the other hand, for instance, when a pixel410bis selected as a current pixel, surrounding pixels411aneighboring the current pixel410bat eight directions do not include any pixel having a drop amount equal to ‘0’. In this case, the edge detector344recognizes “a non-edge region” as an attribute of the current pixel410b, and determines that the current pixel410aconstitutes a target of an increase/decrease control of drop amount.

Current pixels to be concerned are sequentially selected, so that all pixels undergo similar processes. As a result, those targets to be controlled for increase or decrease of drop amount constitute a region, which is determined as an increase/decrease controlling region A2. Then, the increase/decrease controlling region detector341transmits the image forming region A1and the increase/decrease controlling region A2, for instance, as sets of coordinate data to the drop amount increase/decrease controller342. In the present embodiment, surrounding pixels411bare taken at eight directions, that is, four directions being an upward, a downward, a rightward, and a leftward of a current pixel410aor410bplus four directions being an upper rightward, an upper leftward, a lower rightward, and a lower leftward of the current pixel410aor410b. For determination of an increase/decrease controlling region A2, it is determined whether or not the surrounding pixels411bat the eight directions reside in an image forming region A1. The present invention is not limited thereto. For instance, it may be simply determined whether or not surrounding pixels411bat four directions being an upward, a downward, a rightward, and a leftward of a current pixel410aor410breside in an image forming region A1.

The drop amount increase/decrease controller342receives respective data on the image forming region A1and the increase/decrease controlling region A2from the increase/decrease controlling region detector341. The increase/decrease controller342operates on the received data to determine, for each pixel in an input image data400, whether or not the drop amount is to be controlled for increase or decrease. When the drop amount is determined to be controlled for increase or decrease, the controller342serves as a module adapted to operate on a set of drop amount increase/decrease control data D1, to calculate an increment or a decrement of the drop amount. Then, this module executes an increase/decrease process of drop amount. More specifically, the drop amount increase/decrease controller342sequentially selects pixels in the input image data400, as current pixels. When a pixel selected as a current pixel belongs, for instance inFIG. 7, to a blank region A3constituting no part of an image forming region A1, no increase/decrease process of drop amount is determined to be executed. When the current pixel belongs to an increase/decrease controlling region A2constituting part of the image forming region A1as illustrated inFIG. 7, an increase/decrease process of drop amount is determined to be executed. When the current pixel belongs to an edge region A4constituting part of the image forming region A1outside the increase/decrease controlling region A2as illustrated inFIG. 7, no increase/decrease process of drop amount is determined to be executed.

Further, the drop amount increase/decrease controller342is functional to determine an attribute of a current pixel in accordance with a density at the current pixel. The increase/decrease controller342is further functional to increase or decrease a normal increment or decrement in an increase/decrease process of drop amount of ink, or suspend the increase/decrease process, depending on the attribute as determined. It is noted that definitions (conditions) of regions in image data400in the present embodiment are as set forth in a list inFIG. 8.

More specifically, the drop amount increase/decrease controller342is adapted to sequentially select pixels in an input image data400, as current pixels, and calculate drop amounts for the pixels. The increase/decrease controller342is further adapted to determine whether a current pixel resides in a high density region, an intermediate density region, or a low density region. When the current pixel is determined as residing in the high density region, it should be a solid part of a bar code, character, or the like. Accordingly, a process of increasing the drop amount is determined to be executed. On the other hand, when the current pixel is determined as residing in the intermediate density region or the low density region, the pixel may not be any solid part but should be a highlight part or a non-highlight part. Accordingly, the current pixel is determined to be a target of an increase/decrease process of drop amount.

Such being the case, an increase/decrease process of drop amount is executed in accordance with a density at a current pixel. As a result, those pixels having enlarged dot gains with increased drop amounts can be distinctive over other pixels, preventing a granular feeling from appearing on an image.

Images include local regions in which neighboring pixels have drop amounts both residing in a high density region. Such local regions may be places where print qualities are emphasized like bar codes or characters. The drop amounts of ink at the neighboring pixels are both controlled to uniformly increase. This control enhances the degree of filling gaps at pixels associated with discharge-failing nozzles, even if the nodes correspond to pixels at narrow bars of bar codes or in wide bars or characters. Therefore, white lines have reduced tendencies to be distinctive, permitting print qualities of bar codes and characters to be retained high.

When the drop amount increase/decrease controller342operates to reduce an increment or decrement in a low density region, a pixel density comparator344bworks to determine if a given drop amount resides within a reducible range. More specifically, the pixel density comparator344bis operable, to make a comparison between a given drop amount, for instance, when printing and an increment or decrement of the drop amount. If the increment or decrement of drop amount has an absolute value greater than the given drop amount when printing, the width of the increment or decrement of drop amount is controlled. This is done to avoid having a drop amount incremented or decremented to be smaller than a minimum value (e.g. drop amount ‘1’). If the drop amount when printing is equal to or smaller than the minimum value (drop amount=‘1’), the pixel density comparator344bis controlled to suspend an associated increase/decrease process. These control operations are effective to reduce the width of an increment or decrement of the drop amount in regions of pixels having small drop amounts, such as low density regions in highlight parts or the like. This effect can prevent a granular feeling from appearing on an image.

In the present embodiment, the increase/decrease controlling region detector341is configured with a function of detecting an image forming region A1. However, the present invention is not limited thereto. For instance, the increase/decrease controlling region detector341may be integrated with the drop amount increase/decrease controller342, to provide a unit. This unit may be adapted to detect an image forming region A1and an increase/decrease controlling region A2at a drop amount increase/decrease controller342thereof.

Further, the drop amount increase/decrease controller342is operable to execute a prescribed increase/decrease process of drop amount to the increase/decrease controlling region A2. This increase/decrease process employs a method based on a set of drop amount increase/decrease control data D1stored to hold in the memory350. This method includes repeating applying drop amount increase/decrease patterns of drop amount increase/decrease control data D1over an entire image, to execute the increase/decrease process of drop amount. When doing so, definition patterns D11or definition patterns D12are selected as necessary to apply as drop amount increase/decrease control data D1.

More specifically, the drop amount increase/decrease controller342employs a definition pattern D11(i.e. definition pattern inFIG. 5Cformed by repeating patterns inFIG. 5Aover an entire image) as a set of drop amount increase/decrease control data D1. The increase/decrease controller342is operable, as illustrated inFIG. 9, to apply the definition pattern D11to image data400, to execute an increase/decrease process of drop amount based on a increment or decrement (of an increase or decrease width ±2) depending on a position of the increase/decrease controlling region A2. Or else, the drop amount increase/decrease controller342employs a definition pattern D12(i.e. definition pattern inFIG. 5Dformed by repeating patterns inFIG. 5Bover an entire image) as a set of drop amount increase/decrease control data. The increase/decrease controller342is operable, as illustrated inFIG. 10, to apply the definition pattern D12to image data400, to execute an increase/decrease process of drop amount based on an increment or decrement (±2) of drop amount depending on a position of the increase/decrease controlling region A2.

Such being the case, the definition pattern D11inFIG. 5Cor the definition pattern D12inFIG. 5Dis employed to execute an increase/decrease process of drop amount. By doing so, the sum of increments and decrements of drop amounts at pixels constituting targets of increase/decrease processes becomes a ‘0’. This permits the drop amount at each pixel to be determined without changing a drop amount of ink per unit area of an image. If any drop amount after an increase or decrease of drop amount exceeds the range of a maximum drop amount, the drop amount may be limited, and increase/decrease processes in neighboring regions may also be limited.

The image outputting interface343serves as a module adapted to control drives for ink heads110aof each color, governing an entirety of image forming process. In the present embodiment, the image outputting interface343is operable to drive ink heads110ato have their nozzles111adischarge drop amounts. This operation is performed in response to image data400as processed for increases and decreases of drop amounts at the drop amount increase/decrease controller342.

(Method of Reducing the Degradation of Image Quality)

With the foregoing configuration, the function of reducing the degradation of image quality can be exhibited to thereby implement a method of reducing the degradation of image quality as an embodiment of the present invention.FIG. 11shows in a flowchart an outline of the method of reducing the degradation of image quality according to the embodiment. Description is now made of an example in which increase/decrease processes are executed on image data400. This is done to make increments and decrements based a set of drop amount increase/decrease control data D1, so that the sum of increments and decrements at pixels neighboring each other becomes a ‘0’. It is noted that in the present embodiment, characters or the like are printed on a background where the drop amount is ‘0’.

First, the control flow enters a printing. Then, at a step S101, the job data receiving interface331receives image data400included in a job data, and transmits it to the image formation controller340. At a step S102, the increase/decrease controlling region detector341in the image formation controller340receives and analyzes the data, to detect an image forming region A1. More specifically, as illustrated inFIG. 6A, the image data400is analyzed pixel-wise, to detect a region in which pixels have drop amounts unequal to ‘0’, as the image forming region A1. Then, the increase/decrease controlling region detector341transmits a set of data on the detected image forming region to the edge detector344.

The edge detector344detects a region in which pixels selected as current pixels and their surrounding pixels all reside in the image forming region A1, as an increase/decrease controlling region A2. More specifically, the edge detector344sequentially selects each pixel in the input image data400as a current pixel. The edge detector344determines whether or not the current pixel as selected and surrounding pixels thereabout are all included in the image forming region A1, to detect the increase/decrease controlling region A2. The edge detector344transmits a set of data on the increase/decrease controlling region A2to the drop amount increase/decrease controller342.

At a step S103, the drop amount increase/decrease controller342analyzes the image data400, and determines whether or not an increase/decrease process of drop amount is to be executed for each pixel in the image data400. More specifically, at the step S103, as illustrated inFIG. 7, if a current pixel as selected resides in an edge region A4or in a blank region A3not included in the image forming region A1, the increase/decrease process of drop amount is determined not to be executed (NO at the step S103). Then, the increase/decrease process is skipped, and at a step S106, it is determined whether or not the scan is completed for all pixels.

On the other hand, at the step S103, when the current pixel as selected resides in the increase/decrease controlling region A2, the pixel is determined to be a target of the increase/decrease process of drop amount (YES at the step S103). Then, at a step S104, a set of drop amount increase/decrease control data D1is read from the memory350, and at a step S105, a drop amount in the increase/decrease controlling region A2is increased or decreased. For the determination above, if for instance, a definition pattern D11is selected as the set of drop amount increase/decrease control data D1, the increase/decrease process of drop amount of any current pixel is executed as illustrated inFIG. 9. That is, the execution follows an increase/decrease pattern defined in a position corresponding to the current pixel in the definition pattern D11. Further, if, for instance, a definition pattern D12is selected as the set of drop amount increase/decrease control data D1, the increase/decrease process of drop amount of any current pixel is executed as illustrated inFIG. 10. That is, the execution follows an increase/decrease pattern defined in a position corresponding to the current pixel in the definition pattern D12.

Then, at the step S106, the operational processor330determines whether or not the entirety of the image data400is scanned. If the entirety of the image data400is not scanned (NO at the step S106), processes executed at the steps S102to S105are repeated. On the other hand, when the entirety of the image data400is scanned (YES at the step S106), associated processes are ended, and ink heads110aare controlled to form an image on a printing medium10.

(Method of Determining an Increase/Decrease Process)

Description is now made into details of the determination at the step S103in the flowchart shown inFIG. 11. At the step S103, it is determined whether or not a current pixel is included in the increase/decrease controlling region A2. Moreover, at the step S103, an attribute of the current pixel is determined in accordance with a density at the current pixel. Further, at the step S103, the increase/decrease process of drop amount is changed in accordance with the determined attribute.FIG. 12sows in a flowchart a method of determining an increase/decrease process at the step S103.

First, at a step S201, the edge detector344receives a combination of information on a current pixel as a target of determination (such as coordinate data of pixels, drop amounts, color information), and information on the image forming region A1detected at the step S102.

Next, at a step S202, the drop amount increase/decrease controller342first determines whether or not the current pixel as selected resides in the edge region A4. More specifically, the edge detector344operates on data of the image forming region A1, to detect if the current pixel and neighboring surrounding pixels are all included in the image forming region A1. Then, the edge detector344determines whether or not any edge region is recognized as an attribute of the current pixel.

If an edge region is recognized as an attribute of the targeted current pixel (YES at the step S202), the control flow goes to a step S203, where the pixel is determined to be untargeted for any increase/decrease process, to enter a subsequent process. On the other hand, at the step S202, if the current pixel is determined as residing in the increase/decrease controlling region A2(to be an image forming region and non-edge region), a drop amount to the pixel is calculated by the drop amount increase/decrease controller342. Then, the increase/decrease controller342determines an attribute of the current pixel in accordance with the density. Then, the controller342determines whether the current pixel is a high density region, an intermediate region, or a low density region, in accordance with the determined attribute.

More specifically, the drop amount increase/decrease controller342first determines at a step S204whether or not the current pixel as selected has a drop amount equal to or smaller than a prescribed lower threshold. If the current pixel as selected has a drop amount equal to or smaller than the lower threshold (YES at the step S204), then at a step S206the current pixel is determined as a low density region. Then, at a step S207, an increment for decrement of drop amount for the increase/decrease process is determined to be reduced in accordance with a drop amount of the pixel.

For this reduction, there is employed a method. The method includes the drop amount increase/decrease controller342making a comparison between, e.g., a given drop amount when printing and an increment or decrement of the drop amount. If the increment or decrement of drop amount has an absolute value greater than the drop amount when printing, the increase/decrease controller342controls the increment or decrement of drop amount. This is made not to have any incremented or decremented drop amount smaller than a minimum value (e.g. drop amount ‘1’). The control may be made to reduce the increment or decrement of drop amount, for instance, from a normal increment or decrement of ±2, to ±1. Further, if the drop amount when printing is equal to or smaller than the minimum value (drop amount=‘1’), the drop amount increase/decrease controller342operates for a control to suspend the increase/decrease process.

On the other hand, at the step S204, if the current pixel has a drop amount exceeding the prescribed lower threshold (NO at the step S204), the control flow goes to a step S205. At the step S205, the drop amount increase/decrease controller342determines whether or not the current pixel has a drop amount equal to or larger than a prescribed upper threshold.

At the step S205, if the current pixel has a drop amount equal to or larger than the prescribed upper threshold (YES at the step S205), the control flow goes to a step S208, where the current pixel is determined as a high density region (the increase/decrease controlling region A2inFIG. 7). Then, at a step S209, drop amounts of pixels are uniformly increased.

At the step S205, if the current pixel has a drop amount smaller than the prescribed upper threshold (NO at the step S205), the control flow goes to a step S210, where the current pixel is determined as an intermediate density region. Then, at a step S211, the increase or decrease width of a drop amount to be increased or decreased is determined to be a normal increase or decrease width. Each increase/decrease process is executed to make zero the sum of increments and decrements of drop amounts at targeted pixels.

Then, the drop amount increase/decrease controller342makes a transfer of determination results of increase/decrease processes, to a subsequent step (the step S104inFIG. 11). InFIG. 11, at the step S104as well at the next step S105, drop amounts of current pixels are incremented or decremented in accordance with determination results of increase/decrease processes shown inFIG. 12. The image outputting interface343is responsive to image data400subjected to such increase/decrease processes, to drive ink heads110ato discharge drop amounts from their nozzles111a.

According to the present embodiment, even if a certain nozzle111ais failing in discharge, the gap is filled with dot gains of ink droplets21discharged as increased drop amounts at nozzles neighboring thereto in the main scan direction (the X direction). Therefore, white lines have reduced tendencies to get distinctive. In the past, as illustrated inFIG. 13A, upon occurrence of a discharge failure at a nozzle111b, drop amounts (5 drops) of a received image data400were used for a printing process, without increasing or decreasing. As a result, as illustrated inFIG. 13B, a white blank line appeared after the printing process. The presence of a blank gap reduced the reading accuracy of a bar code, as an issue. This has been significant when the content of printing includes targets to be optically read, such as ordinary bar codes or two-dimensional bar codes.

In the present embodiment, even if a failure in discharge has occurred at or on a narrow bar or wide bar printed as a solid black part of a bar code, a resultant blank gap is filled, as illustrated inFIG. 9andFIG. 10, with dot gains of ink discharged as increased drop amounts to neighboring pixels. Therefore, white blank lines due to discharge-failing nozzles111bcan have reduce tendencies against getting distinctive.

In particular, when the content of printing includes targets to be optically read, such as ordinary bar codes or two-dimensional bar codes, even if a failure in discharge has occurred at or on a narrow bar or wide bar printed as a solid black part of a bar code, a blank gap due to missing dots at or on a narrow bar or wide bar can be filled. Therefore, the reading accuracy of bar codes can be prevented from getting reduced.

Pixels in image forming regions such as those of bar codes or characters have neighboring pixels at both sides thereof each printed with one or more drops discharged thereon.

Such image forming regions may be places where print qualities are emphasized. Increase/decrease processes of drop amount of ink are executed between neighboring pixels at both sides simply for such image forming regions. Therefore, even if failures in discharge have occurred at local nozzles, the image quality of an entire image can be retained, as necessary, permitting processing times for increase/decrease processes of drop amount to be suppressed minimum.

In particular, in the present embodiment, the definition pattern D11or D12is used as a set of drop amount increase/decrease control data D1defining increments and decrements of drop amounts associated with pixel positions. With this help, an increase/decrease process of drop amount is executed at each current pixel, so that the sum of increments and decrements of drop amounts at pixels targeted for increase/decrease processes becomes a ‘0’. Accordingly, despite that drop amounts of ink are increased or decreased at targeted pixels, the drop amount of ink per unit area of an image can be unchanged, suppressing variations in density of the image due to increase/decrease processes of drop amount of ink. Further, the increase/decrease range of drop amount of ink is limited to be identical to increase/decrease ranges of drop amounts of ink at neighboring pixels. Therefore, the drop amount of ink can be kept from increasing in an endless manner, preventing occurrences of print-through conditions due to excessive drop amounts of ink.

It is noted that the definition pattern D12is used for an increase/decrease process of drop amount. In this process, two nozzles111aand111aneighboring two sides of a discharge-failing nozzle111bin the main scan direction (X direction) are combined as a set, to execute an increase/decrease process of drop amount in a unit of the set. More specifically, the drop amount of ink discharged from one nozzle111a(for instance, the nozzle111aneighboring the left side of the discharge-failing nozzle111binFIG. 10) is increased. To the contrary, the drop amount of ink discharged from the other nozzle111a(for instance, the nozzle111aneighboring the right side of the discharge-failing nozzle111binFIG. 10) is decreased. That is, the increase/decrease process of drop amount is to be executed in the unit a set of nozzles111aand111a. In this increase/decrease process of drop amount, either of the two nozzles111aand111aconstituting the set has to discharge droplets of ink in an increased drop amount. Therefore, the region of a pixel associated with a discharge-failing nozzle111bhas an enhanced tendency to be filled with the greater drop amount of ink droplets, allowing for an increased difficulty to get distinctive.

In the present embodiment, an image is analyzed to execute an increase/decrease process of drop amount for a current pixel, simply when the current pixel belongs to an image forming region A1in which drop amounts of pixels are unequal to ‘0’. Therefore, even when having a discharge-failing nozzle111b, the print quality of an entire image can be retained at a required quality, permitting processing times for increase/decrease processes of drop amount to be suppressed minimum.

Further, in the present embodiment, an edge region A4is defined as a set of pixels residing in an image forming region A1, and neighboring pixels not residing in the image forming region A1. Then, an increase/decrease controlling region A2is detected as part of the image forming region A1excluding the edge region A4, and an increase/decrease process of drop amount is executed simply on the increase/decrease controlling region A2. Therefore, drop amounts for pixels in the edge region A4are unchanged, keeping edge parts from getting undulated, thick, or thin. This affords to avoid giving undulations to edges (such as boundaries fronting space bars) of narrow bars or wide bars printed as solid black parts of bar codes, causing the reading accuracy of bar code to be reduced.

According to the present embodiment, neighboring pixels both included in an image forming region A1may have drop amounts both equal to or smaller than a prescribed lower limit. In such a case, control is made to reduce the increase or decrease width of drop amount in the increase/decrease process, or suspend the increase/decrease process. Therefore, in low density regions, such as highlight regions, where pixels have small drop amounts, it is possible to prevent a granular feeling from getting distinctive due to drop amounts to be increased/decreased.

Further, according to the present embodiment, current pixels surrounded by pixels included in an increase/decrease controlling region A2may have drop amounts equal to or larger than a prescribed upper threshold. In such a case, the drop amounts of the current pixels are uniformly increased. Therefore, even if a failure in discharge has occurred at or on a narrow bar or wide bar of a bar code in the image forming region A1in which print qualities are emphasized like bar codes or characters, a resultant blank gap due to the failed discharge at a current pixel is filled. This filling is ensured with dot gains of ink discharged as increased drop amounts to neighboring pixels in the increase/decrease controlling region A2. Therefore, the reading accuracy of bar codes can be kept from getting reduced.

In the embodiment above, the increase/decrease process of drop amount described has been addressed to applications such as printing a bar code or a character on a background assumed as a non-image forming blank region in which drop amounts are equal to ‘0’. However, the present invention is not limited to them. There may be an increase/decrease process of drop amount addressed to applications such as printing a character on a background having a low density or intermediate density in which drop amounts are equal to or greater than ‘1’. It may be addressed to applications such as anti-aliasing edge parts to change in a toned manner. There will be described a modification of the embodiment addressed to applications such as printing a character on a background having a low density or intermediate density.

FIG. 14shows in a block diagram an edge detector344including internal modules according to the modification. It is noted that in the modification those constitutional elements identical to the embodiment above are designated at identical reference signs. Their functions and the like are identical to those in the embodiment, unless otherwise described. Redundant description is omitted.

In the modification, as shown inFIG. 14, the edge detector344includes a drop amount comparator344aand a pixel density comparator344b. They are functional to change the increase/decrease process of drop amount in accordance with drop amount or density differences at pixels surrounding a current pixel.

The drop amount comparator344aserves as a module adapted to calculate a difference of drop amount between neighboring pixels targeted for the increase/decrease process. The module is adapted to compare the difference of drop amount with a prescribed value, to detect edge parts of a character or a bar code. The module then determines presence or absence of the increase/decrease process.FIGS. 15A and 15Billustrate patterns of combinations among a current pixel and neighboring pixels in previous and subsequent positions. Those patterns are used for detecting edge regions A4on backgrounds of a low density and an intermediate density.FIGS. 16A and 16Billustrate presence or absence of an increase/decrease process to be determined for every region in image data400. More specifically, as illustrated inFIGS. 16A and 16B, the image data400includes printing parts for printing bar codes, characters, etc., and such regions (low density region and intermediate density region) that are excluded from the printing parts but have drop amounts unequal to ‘0’. In this regard, the drop amount increase/decrease controller342is operative to change a system or the presence or absence of the increase/decrease process of drop amount, in accordance with kinds and locations of regions, such as edge parts or areas in such regions. The increase/decrease controller342employs results of detection at the drop amount comparator344a, as a basis of operations for such changes.

That is, in this modification, a set of results of detection at the drop amount comparator344ais based on for the edge detector344to calculate variations of drop amounts between a current pixel and neighboring pixels in previous and subsequent positions thereto. The edge detector344is responsive to a difference between the variations, to determine a system of the increase/decrease process. In this modification,FIGS. 15A and 15Beach illustrate a combination of a current pixel being a high density pixel, and previous and subsequent pixels either being a low density or intermediate density pixel. Each combination has a difference of variation equal to or greater than a prescribed value, which is based on to determine the current pixel as being an edge region A4.

For instance,FIG. 16illustrates a pattern1, and a pattern3, andFIG. 16Billustrates a pattern5, and a pattern7. They each include a combination of a current pixel and either neighboring pixel lying astride an edge region of a bar code or character. Such being the case, they each include at either side a combination of a current pixel and one of a previous and a subsequent pixel, the combination being composed of consecutive high density pixels with the current pixel inclusive. At the other side, there is a combination of the current pixel and the other neighboring pixel being a low density or intermediate density pixel. The low density or intermediate density pixel and the current pixel have a variation of drop amount in between greater than a variation of drop amount between the consecutive high density pixels, there being a difference equal to or greater than the prescribed value. In this case, the difference is assumed as being located on an edge part in a printing part. Under this condition, the edge detector344determines the increase/decrease process to be suspended, and operates to send a data of that pixel in the image data400to the image outputting interface343. On the other hand,FIG. 16illustrates a pattern2, and a pattern4, andFIG. 16Billustrates a pattern6. As is illustrated, combinations between a current pixel and either neighboring pixel have their variations of drop amount, with a difference in between equal to or greater than the prescribed value. In this case, the edge detector344determines the location of the difference as being a non-edge region, and operates to send a data of that pixel in the image data400to the pixel density comparator344b.

The pixel density comparator344bserves as a module to make a determination on neighboring pixels, and operates on the basis of a result of the determination to determine presence or absence of an increase/decrease process and a kind of the process. More specifically, the pixel density comparator344bcompares variations of respective drop amounts between current pixel and pixels disposed in a previous and a subsequent position thereto, to determine whether they are pixels in a low density region or pixels in an intermediate region. More specifically, the pixel density comparator344bfirst compares differences of drop amounts between the current pixel and the pixels disposed in the previous and the subsequent position. Then, if the differences are equal to or smaller than a prescribed value, it is determined that as illustrated inFIGS. 17A to 17Cthe previous and subsequent pixels as well as the current pixel all reside in regions formed with equivalent densities. For such regions, a drop amount of the current pixel is detected, and it is determined whether the pixel resides in a low density region, an intermediate density region, or a high density region. Then, in accordance with the density determined, the presence or absence of the increase/decrease process as well as the kind of the process is determined.

For instance, for a current pixel that has a drop amount equal to or smaller than a prescribed lower threshold (i.e. the pattern2inFIG. 16A), the pixel density comparator344bassumes that the current pixel and previous and subsequent pixels belong to a low density region. Then, it determines that the increase or decrease width of drop amount in the increase/decrease process should be reduced, or that the increase/decrease process should be suspended. It is noted that in this modification the increase/decrease widths for a normal increase/decrease process are ±2 drops, and an absolute value thereof being drop amount=2 is taken as the lower threshold.

When reducing the increase/decrease widths for low density regions, the pixel density comparator344bdetermines that a given drop amount can be reduced within the range. More specifically, the pixel density comparator344bcompares, for instance, a drop amount to be given when printing and a drop amount to be increased/decreased. If the increasing/decreasing drop amount is greater in absolute value than the drop amount when printing, the comparator344bcontrols increase/decrease widths of the increasing/decreasing drop amount. This is done so that an increased/decreased drop amount does not become smaller than a minimum value (e.g. drop amount ‘1’). If the drop amount when printing is equal to or smaller than the minimum value (drop amount=‘1’), the pixel density comparator344boperates for control to suspend the increase/decrease process. The foregoing control operations reduce increase/decrease widths of drop amount in low density regions, such as highlight regions, in which pixels have small drop amounts. Such control can prevent an image from having a granular feeling.

Further, if the current pixel is given a drop amount equal to or higher than a prescribed lower threshold and equal to or lower than a prescribed upper threshold (i.e. the pattern6inFIG. 16), the pixel density comparator344boperates as follows. That is, the comparator344bassumes that the current pixel and a previous and a subsequent pixel belong to an intermediate density region, and executes a process of canceling out increments and decrements between neighboring pixels. For instance, when the drop amount of a certain pixel is set to ‘+2’, the drop amount of a pixel neighboring that pixel is set to ‘−2’. Such being the case, the sum of increments and decrements between pixels neighboring each other is set to ‘0’. For the current pixel and the previous and the subsequent pixel, increments and decrements of their drops are determined so that the drop amount per unit area is unchanged.

Further, if the current pixel is given a drop amount equal to or higher than the prescribed upper threshold (i.e. the pattern4inFIG. 16A), the pixel density comparator344boperates as follows. That is, the comparator344bassumes that the current pixel and a previous and a subsequent pixel belong to a high density region, and operates to uniformly increase drop amounts of the current pixel and the previous and the subsequent pixel. Therefore, even if a failure in discharge has occurred on a high density region in an image forming region in which print qualities are emphasized like bar codes or characters, a resultant blank gap is filled out. There is a reduced tendency to produce a white line. It is noted that the upper threshold is set to a drop number at which the effect of pixel drop saturates, so that the dot gain will not increase even if the drop number is still increased.

As will be seen from the foregoing description, this modification handles the presence or absence of an increase/decrease process of drop amount between neighboring pixels, and kinds of the process, which are listed in a table inFIG. 18. The pixel density comparator344bdetermines a kind of increase/decrease process of drop amount, and transmits data thereon to the image outputting interface343.

Description is now made of kinds of increase/decrease process of drop amount. As shown inFIG. 18, no increase/decrease process is executed while the current pixel resides in a blank region outside the image forming region, where no pixel (drop number>‘0’) can be targeted for increase or decrease of drop amount.

No increase/decrease process is executed, either, for any current pixel of high density that has a previous and a subsequent pixel either residing on a low density region or an intermediate density region in an image forming region. This is because the current pixel resides in an edge region. This situation corresponds to the pattern1and the pattern3inFIG. 16A, and the pattern5and the pattern7inFIG. 16B.

In this modification, no increase/decrease process is uniformly executed at edge parts between the image forming region and the blank region outside the image forming region. However, there may be a determination made as to whether or not an increase/decrease process should be executed in accordance with the magnitude of a difference of drop amount between neighboring pixels. For instance, such as when the image forming region neighbors a region being no high density region, the presence or absence or the system of increase/decrease process may be changed. This change may depend on whether the side on the region being no high density region is a low density region or an intermediate region.

Current pixels may have a drop number uniformly increased when any current pixel and a previous and a subsequent pixel thereto all reside in a high density region (i.e. the pattern4inFIG. 16A).

When the current pixel and a previous and a subsequent pixel thereto all reside in a low density region (i.e. the pattern2inFIG. 16A), the increase/decrease process may be suspended if the density at the pixel is equal to or smaller than a constant value. The increase/decrease process may be executed with a reduced increase/decrease width, when the density at the pixel exceeds the constant value. When the current pixel and a previous and a subsequent pixel thereto all reside in an intermediate density region (i.e. the pattern6inFIG. 16B), the increase/decrease process may be executed, canceling out increments and decrements. This should be done so that, between the current pixel and the previous and the subsequent pixel, the sum of increments and decrements becomes ‘0’.

In this modification, no increase/decrease process is uniformly executed at edge parts between a high density region and non-high density regions (i.e. low density region and intermediate density region). However, there may be a determination made as to whether or not an increase/decrease process should be executed in accordance with the magnitude of a difference of drop amount between neighboring pixels. For instance, such as when a high density region neighbors either non-high density region, the presence or absence or the system of increase/decrease process may be changed. This change may depend on whether the side on the non-high density region is a low density region or an intermediate region.

In this modification, no increase/decrease process is executed, if the difference of drop amount is equal to or larger than a prescribed value between a current pixel targeted for an increase/decrease process and a previous and a subsequent pixel relative to the current pixel. This condition is retained even on image data including a background formed with low densities or intermediate densities. Even when e.g. a bar code or character has a background, and drop amounts are unequal to ‘0’ in regions else than the bar code or character, edge regions of the bar code or character can be detected to keep drop amounts unchanged in the edge regions. Edge regions are thus kept from getting undulated, or thin or thick, affording to avoid having a degraded bar code reading accuracy.

The present application claims the benefit of priority under 35 U.S.C. §119 to Japanese Patent Application No. 2010-267723, filed on Nov. 30, 2010, the entire content of which is incorporated herein by reference.