Tag: Epson printhead

Waveform, Temperature, and Voltage Coordinated Intelligent Regulator — “SUPERINKS” Ink

In digital printers, waveform, temperature, and voltage form an interconnected closed-loop system that collectively determines printhead performance—including droplet precision, stability, and ejection efficiency. Their core relationship: waveform is the control logic backbone, voltage executes the waveform, and temperature indirectly affects their alignment by altering ink and printhead properties. Here’s a concise breakdown:

I. Waveform and Voltage: Direct Instruction-Execution Link

Voltage physically expresses the waveform, with the waveform defining voltage parameters (peak, duration, pulse shape) and voltage output validating the waveform’s effectiveness:

1. Waveform dictates voltage’s “time-intensity” profile

A waveform is a voltage-time curve. For example, its “main ejection pulse” uses high voltage (30–50V) to drive piezoelectric crystals, expelling droplets of set volume; a subsequent “damping pulse” (5–10V) suppresses residual vibrations, preventing “satellite droplets.” Voltage peak, timing, and slope are precisely set via waveform parameters (e.g., V1/V2, t1/t2).

2. Voltage must match waveform energy needs

Waveforms rely on voltage to deliver actuation energy (≈ voltage²×time/resistance). Insufficient voltage causes undersized droplets or clogs; excessive voltage risks overheating, printhead damage, or messy droplet spread.

II. Temperature: Indirectly Shaping Compatibility

Temperature disrupts waveform-voltage balance by changing ink and printhead properties, requiring adjustments:

• Ink effects:
  • High temps (>35°C) thin ink, risking blurred edges or residual buildup. Fixes: shorter pulses, lower voltage, or stronger damping.
  • Low temps (<25°C) thicken ink, causing clogs or faint prints. Fixes: longer pulses, higher voltage, or pre-ejection bursts.
• Printhead effects:

High temps make crystals more deformable (amplifying voltage force); low temps stiffen them (weakening force). Thus, voltage/waveform intensity must drop in heat and rise in cold to stabilize droplets.

III. Dynamic Balance: Closed-Loop Control

Printers use sensors and algorithms to sync the three:

• Temperature triggers: Sensors (±1°C accuracy) adjust waveform/voltage if temps leave 25–35°C, keeping droplets stable.
• Voltage fluctuations: Algorithms tweak pulse length to maintain energy (longer for low voltage, shorter for high).
• Safety limits: Waveforms cap voltage at high temps (e.g., ≤30V at 50°C) and shorten pulses at high voltage (e.g., 60V) to prevent damage.

Choose SUPERINKS for Seamless Synergy

Ink stability is key—and SUPERINKS excel here:

• Temperature resistance: Proprietary formula limits viscosity swings to ≤8% (35–50°C) and ≤12% (0–25°C), far better than standard inks (20–30%/25%), reducing waveform/voltage tweaks.
• Printhead compatibility: 500+ tests with Epson I3200, Ricoh G5, Konica 1024 ensure perfect surface tension matching, achieving <2% droplet deviation across ±20°C. Crisper details, smoother color transitions.
• Cost/efficiency gains: Stable viscosity cuts voltage adjustments, reducing crystal fatigue by 30% (extending printhead life by 4,000 hours) and lowering waste/operational costs by 15–20%.

Summary

Waveform = “blueprint,” voltage = “force,” temperature = “environment”—SUPERINKS harmonize them all. Choose us for precise, efficient, cost-effective printing.

Analysis of the Relationship Between Ink Viscosity, Temperature and Nozzle Voltage in Digital Printers

In the operation of digital printers, there exists a close dynamic correlation between ink viscosity, temperature, and nozzle voltage. Their coordinated state directly impacts printing quality (such as droplet size, landing precision, color uniformity) and equipment stability. The following provides a systematic explanation from three perspectives: core concepts, interaction mechanisms, and practical implications with regulatory logic.

I. Core Concepts and Individual Functions

1. Ink Viscosity

Viscosity is a physical property that measures the internal friction within ink, directly determining how easily the ink flows:

• Excessively high viscosity: The ink has poor fluidity and is prone to clogging the nozzle, preventing ink droplets from being ejected smoothly and leading to issues like line breaks and ink shortages.
• Excessively low viscosity: The ink is overly thin and tends to spread excessively after ejection, which may result in blurring, color bleeding, or abnormal merging of ink droplets due to insufficient surface tension.

2. Temperature

Temperature is a key factor in regulating ink viscosity, with its effect on viscosity following a clear pattern:

• A rise in temperature → Intensified movement of ink molecules → Weakened intermolecular forces → Reduced viscosity (enhanced fluidity).
• A drop in temperature → Slowed molecular movement → Strengthened intermolecular forces → Increased viscosity (diminished fluidity).

Different types of inks vary in their sensitivity to temperature. For instance, water-based inks are more significantly affected by temperature than solvent-based and UV-curable inks.

3. Nozzle Voltage

Nozzle voltage (driving voltage) determines the ink ejection state by controlling the operational intensity of core components:

• For piezoelectric crystal nozzles: Increased voltage → Greater deformation of the crystal → Faster speed and larger volume of ejected ink droplets; Decreased voltage → Less deformation → Slower speed and smaller volume of ink droplets.
• For thermal bubble nozzles: Increased voltage → Stronger pressure generated by thermal bubbles → Higher kinetic energy of ink droplets; Decreased voltage → Weaker pressure → Insufficient kinetic energy of ink droplets, which may cause deviations in landing positions.

II. Interaction Mechanism: Dynamic Balance Between Power and Resistance

1. Direct Correlation Between Temperature and Viscosity

Temperature is the core driving factor behind changes in viscosity, and there is a significant negative correlation between the two:

• When the ambient temperature rises (e.g., from 25℃ to 35℃), the viscosity of Epson weak solvent ink may decrease from 4.2cP to 3cP; when solvent-based ink is cooled from 25℃ to 15℃, its viscosity may increase from 8cP to 10cP.
• This correlation is universal. The order of sensitivity to temperature among different ink types (UV ink, water-based ink, solvent-based ink) is: UV ink ＞ water-based ink ＞ solvent-based ink, though the trend of change remains consistent.

2. Adaptation Logic Between Viscosity and Nozzle Voltage

Nozzle voltage provides the “power” for ink ejection, while viscosity represents the “resistance” to ink flow. They need to be dynamically matched:

• When viscosity increases: The flow resistance of the ink rises, so the nozzle voltage must be increased to enhance the driving force, ensuring that ink droplets can overcome the resistance and be ejected smoothly.
• When viscosity decreases: The ink resistance lessens, so the nozzle voltage should be reduced to weaken the driving force, preventing uncontrolled diffusion of ink droplets due to excessive power.

III. Practical Implications and Regulatory Logic

1. Chain Reaction: Temperature → Viscosity → Voltage

The chain effect of these three factors forms a clear regulatory pathway:

• High-temperature environment (low viscosity):

Chain reaction: Temperature ↑ → Viscosity ↓ → Excessively high ink fluidity (low resistance).

Voltage requirement: Maintaining the original voltage would easily cause ink droplets to be too large and fast, resulting in “blurring”, “ink splattering”, or nozzle leakage. Thus, the voltage needs to be reduced (e.g., in the standard state of 25℃, 15cP, 30V, when the temperature rises to 35℃ and the viscosity drops to 10cP, the voltage should be adjusted to 24-26V).

• Low-temperature environment (high viscosity):

Chain reaction: Temperature ↓ → Viscosity ↑ → Poor ink fluidity (high resistance).

Voltage requirement: Keeping the original voltage would lead to insufficient driving force, causing ink droplets to be ejected weakly and resulting in line breaks or clogging. Therefore, the voltage needs to be increased (e.g., in the standard state of 25℃, 15cP, 30V, when the temperature drops to 15℃ and the viscosity rises to 20cP, the voltage should be adjusted to 34-36V).

2. Dual Regulation Strategy Under Extreme Temperatures

When the temperature exceeds the conventional range (ultra-high temperature ＞ 40℃, ultra-low temperature ＜ 5℃), simply adjusting the voltage is insufficient, and temperature control equipment must be used in conjunction:

• Ultra-high temperature environment: The viscosity may drop below 8cP. Even with reduced voltage, “stringing” (inability to form complete ink droplets) may occur. It is necessary to activate the cooling device to stabilize the ink temperature, followed by appropriate voltage adjustment.
• Ultra-low temperature environment: The viscosity may rise above 30cP. Even with increased voltage, nozzle components (such as piezoelectric crystals) may have insufficient driving force due to slow response at low temperatures. It is necessary to reduce the viscosity using the ink circuit heating device and then make appropriate voltage adjustments.

Summary

The relationship between ink viscosity, temperature, and nozzle voltage can be summarized as: Temperature determines the viscosity baseline, viscosity determines the voltage requirement, and voltage ultimately regulates the state of ink droplets. The core logic is:

• A rise in temperature → A decrease in viscosity → Voltage needs to be turned down (to avoid excessive driving force);
• A drop in temperature → An increase in viscosity → Voltage needs to be turned up (to compensate for increased resistance).

In practical operation, the focus should be on the core goal of “maintaining the stability of ink droplet morphology”. The voltage should be dynamically adjusted based on real-time changes in temperature and viscosity, and temperature control equipment should be used when necessary to ensure printing quality and equipment stability.

Relationship Between Transfer Rate and Secondary Sublimation of Sublimation Inks

The transfer rate of sublimation inks (defined as the efficiency of ink migration from the carrier to the substrate during the initial transfer process) and secondary sublimation (referring to the phenomenon where dyes already adhered to the printed product undergo re-sublimation and migration under subsequent high-temperature conditions) are core indicators that are closely interrelated and mutually influential. In essence, both concepts revolve around the “stability and migration rules of dye molecules,” and their specific relationship can be analyzed from three dimensions: “the impact of transfer rate on secondary sublimation,” “the reverse effect of secondary sublimation on transfer performance,” and “the logic of collaborative optimization.”

I. Core Logic: Transfer Rate Determines the “Basic Probability” of Secondary Sublimation

The level of transfer rate directly affects the residual state of dye molecules on the substrate, including molecular quantity, distribution density, and bonding firmness—all of which serve as the core prerequisite for the occurrence and severity of secondary sublimation. It is crucial to note that a “higher transfer rate does not equate to better performance”; instead, it must be balanced with the “dye fixation effect” to ultimately determine the risk threshold of secondary sublimation.

1. Excessively Low Transfer Rate: Low Risk of Secondary Sublimation but Poor Print Quality

When the initial transfer rate is insufficient (e.g., due to inadequate temperature or pressure leading to incomplete ink migration), the total amount of dye molecules attached to the substrate is limited, and most remain concentrated on the surface layer (without penetrating deep into the substrate’s fibers or coating):

• From a quantitative perspective: The base number of dye molecules available for secondary sublimation is small. Even when exposed to high temperatures later, only a minimal amount of molecules will migrate, resulting in no significant “color fading or pattern blurring.”
• From a qualitative perspective: Surface-bound dyes that fail to penetrate deeply are prone to detachment during washing or friction, which in turn masks the impact of secondary sublimation. However, this essentially leads to poor print durability (characterized by light colors and easy fading)—a scenario defined as “false low risk caused by low transfer rate.”

2. Excessively High Transfer Rate (with Insufficient Fixation): Sharply Increased Risk of Secondary Sublimation

If an “excessively high transfer rate” is achieved by overly raising the temperature or extending the transfer time, but the dye molecules fail to form stable bonds with the substrate (e.g., the molecular gaps in polyester fabrics do not fully “lock in” the dyes, or the ceramic coating is not completely cured), the dye molecules on the substrate will be in a “highly saturated yet highly active” state:

• The dye molecules are only physically filled on the surface or shallow layer of the substrate, without forming chemical adsorption or intermolecular forces.
• When exposed to temperatures above 120°C (such as high-temperature ironing, drying, or summer exposure) afterward, these active dye molecules easily regain kinetic energy, break through surface constraints, and undergo secondary sublimation. This manifests as “print fading, pattern edge blurring (with dyes migrating to non-patterned areas), and color unevenness”—issues that are particularly prominent on light-colored substrates or fine patterns.

3. “Moderate Transfer Rate with Sufficient Fixation”: Controllable Risk of Secondary Sublimation

The ideal scenario is characterized by “up-to-standard transfer rate (60%-80%, varying by substrate) + sufficient dye fixation”:

• Up-to-standard transfer rate: Ensures color saturation and clarity meet requirements, with an adequate amount of dye molecules penetrating deep into the substrate (e.g., the amorphous regions of polyester fibers or the micro-pores of ceramic coatings).
• Sufficient fixation: Through precise temperature and time control, dye molecules form stable bonds with the substrate—such as hydrogen bonds and van der Waals forces between polyester molecular chains and dye molecules, as well as chemical cross-linking between the coating and dyes.
• In this case, the number of “free dye molecules” capable of participating in secondary sublimation is extremely small. Even when exposed to conventional high temperatures (e.g., fabric ironing at 120-150°C) later, only negligible migration occurs, which does not affect the print’s appearance or durability.

II. Reverse Effect: Secondary Sublimation as a “Touchstone” for the “Effectiveness” of Transfer Rate

The occurrence of secondary sublimation essentially serves as a test of the “quality” of the initial transfer. A high transfer rate value does not necessarily indicate good transfer performance; instead, the “effective transfer rate”—defined as the proportion of dyes that are truly fixed on the substrate and not easily migrated—must be evaluated based on the stability of secondary sublimation.

• Case 1: Sample A has an initial transfer rate of 85%, but after a high-temperature test at 180°C, the color loss rate reaches 30% (indicating severe secondary sublimation). This reveals that its “effective transfer rate” is only 55% (85% × 70%), with a large number of dyes remaining in a free state—classified as “invalid high transfer rate.”
• Case 2: Sample B has an initial transfer rate of 75%, but after a high-temperature test at 180°C, the color loss rate is only 5% (indicating slight secondary sublimation). Its “effective transfer rate” reaches 71.25% (75% × 95%). Although the initial transfer rate is slightly lower, the actual transfer quality is significantly better.

It is evident that the stability of secondary sublimation helps identify “false high transfer rates.” Some processes (e.g., excessive high temperature) can improve short-term transfer rates but compromise dye fixation, increasing the risk of secondary sublimation and ultimately reducing print durability (such as fading of outdoor signs or blurring of patterns on clothing after washing).

III. Collaborative Optimization: Core Strategies for Balancing Transfer Rate and Secondary Sublimation

To achieve both “high transfer rate” and “low risk of secondary sublimation,” process optimization must focus on the “balance between dye molecule migration and fixation,” with the following core strategies:

1. Precisely Control Initial Transfer Parameters to Avoid Extreme Settings

• Temperature: Avoid blindly pursuing excessively high temperatures (e.g., control the temperature at 190-210°C for polyester fabrics instead of exceeding 230°C—temperatures above 230°C easily cause excessive dye sublimation, making it difficult for dyes to fully bond with the substrate). Ensure that while dyes are fully sublimated, there is sufficient time for them to adhere to the substrate.
• Time: Avoid overly short durations (which result in incomplete transfer) or overly long durations (which lead to reverse dye migration and substrate aging). For conventional fabrics, control the time at 20-30 seconds; for rigid substrates (e.g., ceramics), set it to 30-60 seconds.
• Pressure: Ensure tight adhesion between the carrier and the substrate (to minimize ink loss) without damaging the substrate (to prevent fiber or coating structure damage, which would impair dye fixation).

2. Select Inks and Substrates with “High Fixation Performance”

• Inks: Prioritize “high-purity, low-volatility” sublimation dyes (e.g., disperse dyes C.I. Disperse Red 60 and Blue 359). Their molecular structure enables better bonding with polyester or coatings, reducing the number of free molecules.
• Substrates: For fabrics, choose high-count, high-density polyester (with more regular fiber gaps that facilitate dye locking); for rigid products, select “cross-linked coatings” (e.g., silica-modified coatings for ceramic mugs, which can form chemical bonds with dyes).

3. Incorporate “Post-Treatment Processes” to Enhance Dye Fixation

• For Fabrics: After transfer, conduct “low-temperature setting” (120-140°C for 5-10 seconds) to promote polyester fiber shrinkage and further lock in dye molecules.
• For Rigid Substrates: After transfer, perform “coating curing” (e.g., baking ceramic mugs at 150°C for 20 minutes) to enable full cross-linking between the coating and dyes, reducing the likelihood of secondary sublimation.

Conclusion: A Two-Way “Cause-Effect + Inspection” Relationship Between Transfer Rate and Secondary Sublimation

• Cause-Effect Relationship: The “level and quality” of the initial transfer rate—specifically, whether it is accompanied by sufficient fixation—directly determines the risk level of secondary sublimation. A low transfer rate (even with good fixation) results in low risk but poor quality; a high transfer rate (with poor fixation) leads to high risk; a moderate transfer rate (with good fixation) ensures controllable risk.
• Inspection Relationship: The stability of secondary sublimation can reversely verify the “effective transfer rate” of the initial transfer, preventing misleading conclusions from “false high transfer rates.”
• Core Goal: The objective is not to pursue a “100% transfer rate,” but to achieve a balance between “up-to-standard transfer rate” and “stable secondary sublimation” through process optimization—ultimately ensuring the print’s color performance and long-term durability.

How do temperature changes in the environment affect printing color results?

In daily printing operations, a common phenomenon has attracted widespread attention: when using the same ink, equipment, materials, and keeping printing parameters constant, the color of the same item printed in the morning, noon, and evening often shows slight differences. The causes and solutions to this phenomenon are worthy of in-depth discussion.

 According to research conducted by our company, fluctuations in ambient temperature are the core factor contributing to this phenomenon. Our company points out that temperature changes directly affect the viscosity of the ink, and such changes in ink viscosity will further impact the ejection force of the nozzles, ultimately resulting in differences in printed colors.

 The viscosity of ink is highly sensitive to temperature. When the ambient temperature rises, the movement of ink molecules intensifies, internal friction decreases, leading to reduced viscosity and enhanced fluidity; conversely, when the temperature drops, molecular movement slows down, internal friction increases, resulting in higher viscosity and weakened fluidity.

Taking common water-based inkjet inks as an example, for every 5-10℃ temperature fluctuation, their viscosity may change by 10%-30%, which is sufficient to significantly affect printing results.

From the perspective of specific mechanisms, when high temperatures lead to low ink viscosity, the ink has strong fluidity and tends to spread when ejected from the nozzles. The speed of ink droplets increases, and their landing points are closer than expected, thereby increasing the ink volume per unit area and causing the color to appear darker;

 when low temperatures result in high ink viscosity, the ink has poor fluidity, requiring the nozzles to exert greater ejection force. This, in turn, leads to slower ink droplet speed, farther landing points, and reduced ink volume per unit area, making the color look lighter.

In addition, temperature changes also affect the spreading and fusion of ink droplets on the material surface. In a high-temperature environment, ink droplets spread rapidly and may over-fuse with surrounding droplets, causing blurred edges and seemingly higher color saturation; in a low-temperature environment, ink droplets spread slowly with clearer edges, but due to insufficient fusion, the color may appear “dry” and the saturation will decrease accordingly.

This issue has caused many inconveniences in fields with high color accuracy requirements, such as advertising printing and packaging printing.

In response, a series of effective measures have been developed in the industry, and choosing an ink with strong adaptability to temperature changes is undoubtedly the key to solving the problem at its source.

Here, we recommend our ink,
which excels in the adaptability of its viscosity to temperature changes. Compared with ordinary inks, our ink not only meets application needs under normal temperatures but also has distinct advantages in special temperature environments: in low-temperature environments, it can maintain low viscosity and better fluidity, avoiding problems such as poor ejection and lighter colors caused by high viscosity;

in high-temperature environments, its viscosity is relatively higher, making the ink less likely to break during ejection, reducing ink droplet spreading and darker colors, and effectively ensuring the stability of printed colors under different temperatures.

Besides selecting high-quality ink, other measures can be taken.

Firstly, control the printing environment temperature and keep it within the 15-25℃ range recommended for the ink, which can be achieved through air conditioning, heating, and constant-temperature equipment.

Secondly, perform constant-temperature treatment on the ink, such as equipping the ink container with a heating belt or a constant-temperature sleeve to ensure the ink temperature remains stable before entering the nozzles;

for large printing equipment, an ink circulation constant-temperature system can be installed for real-time adjustment. Some high-end printers are equipped with a “temperature-parameter linkage” function, which can dynamically adjust printing parameters according to temperature changes.

When the temperature rises, appropriately reduce the inkjet pressure or decrease the ink droplet volume to avoid excessive ink; when the temperature drops, appropriately increase the inkjet pressure or enlarge the ink droplet volume to compensate for insufficient ink.

In addition, adjusting the ICC curve in the color management software using a printing calibration strip (such as a color card) to enable the system to automatically compensate for temperature-induced color differences can further improve the consistency of printing results. By mastering the above knowledge and using suitable ink, when encountering the situation where printed colors change over time, targeted measures can be taken to resolve it, thus ensuring the smooth progress of printing work.

Root Causes and Systematic Solutions for UV Printer Curing Pass Marks

The pass-through phenomenon in UV flatbed and roll-to-roll printers—particularly noticeable when printing solid colors—stems from unavoidable mechanical precision errors.
Theoretically impossible to eliminate entirely, it becomes less visible and impactful on print quality as device precision increases. Below are key causes and targeted solutions:

I. Core Causes of Pass-through
1. Excessively low printing feather value
2. Excessively high printing speed (especially in bidirectional mode)
3. Loose Y-axis drive belt (or insufficient lead screw lubrication)
4. Printhead abnormalities (e.g., ink breakage, clogging)

II. Targeted Solutions
Excessively low printing feather value UV inks have poor leveling and cure rapidly under UV exposure.
✅ Solutions:
Adjust the feather value to 80-100. This compensates for gaps via ink dot overlap, ensuring smoother pattern transitions.

Excessively high speed in bidirectional printing Bidirectional printing can amplify mechanical errors in the printhead’s reciprocating motion, with high speed exacerbating the issue.
✅ Solutions:
For high-precision needs: Switch to unidirectional printing (trading speed for accuracy).
For standard precision needs: Retain bidirectional printing but reduce speed appropriately.

Loose Y-axis belt or lead screw drive issues
Long-term operation may loosen the Y-axis belt (causing unstable transmission) or leave lead screws under-lubricated (leading to jams).
✅ Solutions:
Belt-driven systems: Tighten the belt promptly and adjust tension.
Lead screw-driven systems: Regularly apply lubricant to maintain smooth operation.

Poor printhead condition or nozzle missing
Clogged printheads or uneven ink discharge directly cause intermittent print paths, resulting in obvious pass-through.
✅ Solutions:
Pause printing and clean the printhead with cleaning fluid until ink flows in a continuous, beaded stream (indicating unobstructed nozzles).
Daily maintenance: Print a test strip before daily operation to confirm the printhead is in normal condition.