Patent Grant
7073896
1. Field of the Invention
The invention pertains to the field of inkjetting of fluids and, in particular, to the stimulation of inkjet fluid droplet formation in continuous inkjet systems.
2. Background of the Invention
The use of ink jet printers for printing information on a recording media is well established. Printers employed for this purpose may be grouped into those that use a continuous stream of fluid droplets and those that emit droplets only when corresponding information is to be printed. The former group is generally known as continuous inkjet printers and the latter as drop-on-demand inkjet printers. The general principles of operation of both of these groups of printers are very well recorded. Drop-on-demand inkjet printers have become the predominant type of printer for use in home computing systems, while continuous inkjet systems find major application in industrial and professional environments.
Continuous inkjet printers typically have a print head that incorporates a supply line or system for ink fluid and a nozzle plate with one or more ink nozzles fed by the ink fluid supply. A gutter assembly is positioned downstream from the nozzle plate proximate to the flight path of ink droplets. The gutter assembly catches ink droplets that are not needed for printing on the recording medium.
In order to create the ink droplets, a drop generator is associated with the print head. The drop generator influences, by a variety of mechanisms discussed in the art, the fluid stream within and just beyond the print head. This is done at a frequency that forces thread-like streams of ink, which are initially ejected from the nozzles, to be broken up into a series of ink droplets at a point within the vicinity of the nozzle plate.
The means for selecting printing drops from non-printing drops in the continuous stream in ink drops have been well described in the art. One commonly used practice is that of electrostatically charging and electrostatically deflecting selected drops. A charge electrode is positioned along the flight path of the ink droplets. The function of the charge electrode is to selectively charge the ink droplets as the droplets pass the electrodes. One or more deflection plates positioned downstream from the charge electrodes deflect a charged ink droplet either into the gutter or onto the recording media. For example, the droplets to be deflected to the gutter assembly are charged and those intended to print on the media are not charged.
It is possible to implement schemes by which the charge on (or neutrality of) droplets that are intended to print, is managed through the selective charging of droplets from neighboring nozzles, thereby controlling the induced charge on the droplet selected for printing. The charging sequence of successive drops in a stream is also used to control the electrostatic influence of charged drops on one another. These methods are generally referred to as “guard drop schemes”. These schemes usually imply that the guard droplets neighboring the droplet selected for printing are not selected to print on a specific clock cycle. The implication of this kind of arrangement is that there are more guard drops than droplets selected for printing and the throughput of the system is commensurately reduced, with more ink being guttered than printed. While this may be viewed as a disadvantage, the absolute rate of droplet emission is very high, so that it is possible to maintain practical levels of overall printing throughput for the system as a whole.
The droplet generation process itself has been addressed extensively in the prior art. In its most basic form, the droplet generation process comprises creating a continuous flow of ink through a small orifice, and then employing a stimulus or perturbation to create droplets at a specific frequency. Stimulation is obtained via techniques such as pressure variations induced by heating, the piezoelectric effect or the electrohydrodynamic effect (EHD). In the simplest case, this stimulation is carried out at a fixed frequency that is calculated to be optimal for the particular liquid and matching the natural resonance breakup frequency of the fluid column ejected from the orifice. The spacing of the drops, λ, is related to the jet velocity, v, and stimulation frequency, f, by f λ=v. Drop formation on a stream of ink occurs when a perturbation signal grows on the ink column until the amplitude of the perturbation is such that a drop is formed. As described in the art, the linear theory describes a range of frequencies for which the gain, the rate of growth of a perturbation on a fluid column, is non-zero. The wavelength, λ, corresponding to the drop separation will have to obey λ>πd, where d is the jet diameter, if a particular frequency of stimulation is to grow on the stream and cause stimulated drop break-off.
It is found that the basic droplet creation process also causes satellite droplets to form. Satellite drops or droplets are one or more small droplets interspersed with the main stream of drops, the main drops of the stream being larger drops near the intended volume and spacing desired for optimal printing. Satellite drop formation presents a problem in inkjet printing because of unwanted drop charging effects and drop misting causing contamination of the print head environment and the resulting reduction in print quality.
The specifics of satellite formation, a non-linear process, are described in the art. Satellites form from the filaments of ink that connect the pre-formed drops in the fluid stream as it begins to breakup. The difference in the break-off time of each end of the filament and the resulting momentum exchange in the fluid filaments determine whether slow, fast or intermediate satellites are formed. Slow satellites are overtaken by the larger drop behind it and are termed rearward merging satellites. Fast satellites merge with the main drop ahead of it and are termed forward merging satellites. In the intermediate case, the satellite moves at the same velocity as the drops in the main stream and does not merge with the main drops over the course of several millimeters of travel of the drops. Different levels of stimulation cause the formation of different types of satellites: generally low excitation produces rearward merging satellites and high excitation produces forward merging satellites.
In the implementation of inkjetting systems as described above, some drops are charged as they form, and the charging potential waveform is designed to achieve proper charging of the main drops. As such, the charging potential may be changing rapidly during the formation of satellites. In this instance the charge induced on the separate satellite and main drop is indeterminate and may be significantly different from the intended charge on the main drop. The occurrence of satellite can result in the charge on some main droplets being less than intended, and that on some satellite droplets being rather large. The ultimate charge distribution on the drops is then complicated by the fact that some satellite droplets merge forward into previously emitted main droplets, or merge backwards into following main droplets. The merging of satellite droplets and main drops is problematic if the satellites completely form as separate drops prior to the break-off of the main drops into which the satellites will later merge, an instance in which the charge on the resulting merged drops is most indeterminate. This occurrence is termed a “bad merge” and is further described as either a “bad rearward merge” or a “bad forward merge” depending on whether the said first separated satellite then merges with the main drop behind it or ahead of it, respectively. The result of these effects is that some main droplets, that had been intended to be uncharged or given a specific charge, and to be printed, become at least slightly charged or have their intended charge altered. This leads to them being deflected slightly in their trajectories, and they end up printing at a point that differs significantly from the point at which they were intended to print.
Additionally, in the instance where satellites separate from the main drop after the main drop has separated from the jet, and then merge back into the drop moving forward, the behavior is termed “good forward merging”, and in merging to the rear, “good rearward merging”. These behaviors are termed “good” as both components of the drop are separated from the jet and exposed to the full charging cycle of the charging electrodes.
One solution that has been proposed to address the problem of the control of satellite formation is described in U.S. Pat. No. 4,734,705. The proposed solution comprises stimulating the liquid flow at both a fundamental frequency and at least one other harmonic frequency, typically the second harmonic frequency, and then adjusting the relative amplitude and phase of the at least two stimulation signals to stimulate drop formation in a region of ideal satellite formation.
With the rapid development of inkjet printing technology, the need for increased printing throughput, improved resolution, superlative droplet placement and optimal use of the inkflow has increased. The present invention seeks to address the combination of these requirements.
A continuous inkjet device emits a stream of fluid from nozzles. Droplet break-off is stimulated by the application of external cyclical perturbing stimulus to the stream in a manner that controls the formation of satellite drops. Satellite behavior is controlled by the use of a composite cyclical perturbing signal, composed of at least two frequencies that are not harmonically related, but are related by the ratio of small integers. In one embodiment, the use of two cyclical perturbing signals with frequencies fL and fH having a ratio of M/N, where M and N are integers, and M is not a multiple of N, and N is not a multiple of M produces a repeating drop pattern of either M or N drops at the beat frequency of the combined signal, the constituent drops in said repeating pattern have different satellite formation characteristics. With suitable choice of phase and amplitude of the two component cyclical perturbing signals, at least one drop in the repeating pattern is observed to have favorable satellite behavior, or the absence of satellites, and is optimal for printing. This stimulation method, producing a repeating pattern of drops of different satellite behavior may then be aligned with the phase of a guard drop scheme, in which selected drops in a sequence are purposely charged and guttered in order to specifically reduce electrostatic crosstalk on print-selectable drops. By aligning the phase of the optimal printing drops of the stimulation means with the print-selectable drops of the guard drop scheme, all droplets with sub-optimal satellite behavior are thereby guttered and droplets with optimal satellite behavior are available for printing with great accuracy.
In one aspect of the present invention, we consider the matter of the stimulation required for droplet formation. Preferred methods of drop break-off stimulation in the continuous inkjet system of the present invention include thermal, electrohydrodynamic and piezo-electric. To the extent that the basic mechanisms of droplet formation are well understood and documented, these matters will not be entered upon herein in detail.
In a preferred embodiment of the present invention, the inkjet fluid is stimulated or perturbed with two cyclical perturbation signals, one at a selected lower frequency fL (the first frequency) and one at a higher frequency fH (the second frequency), which higher frequency is not a harmonic of the lower frequency. A more preferred droplet formation stimulation arrangement is that in which the higher frequency has the relationship with the lower frequency as given by equation (1):
fH/fL=M/N (1)
where M and N are small integers, M is not an integer multiple of N and N is not an integer multiple of M. Such a selection of frequencies is referred to in the present specification as being “anharmonic”.
Another constraint on the choice of frequencies is given by the well-established linear theory deriving the gain curve, which describes the gain of a growing signal on the inkjet as a function of wavenumber κ=πd/λ. For non-zero gain and growth of the perturbation frequencies on the ink stream, the wavelength of a given frequency must obey λ>πd. For the two frequency system of our preferred embodiment this requirement becomes λH>πd or λL>(M/N)πd. We allow for the fact that the linear theory describing the gain curve may only be approximate in determining these wavelength limits and that in practice, when non-linearities are considered, some non-zero gain may for example exist for λH<πd.
The combined signal, herein referred to as the net cyclical perturbation, will have a waveform that is dependent on the relative amplitude and phase of the underlying cyclical perturbation signals, but in general will have the form of repeated peaks and valleys, the peaks occurring at times close to the occurrence of peaks of either the component waveform at frequency at fH or at fL. The two signals will add to produce this repeating interference pattern every M cycles of the higher frequency signal or every N cycles of the lower frequency signal, at a third frequency, the beat frequency. This beat frequency is given by equation (2):
fB=fH|(1−N/M)| (2)
It may be shown that, by using a suitable choice of relative amplitude and phase of the signals at fH and fL, droplets may be produced from the fluid jet at the higher frequency, fH, while the repeating pattern of satellite drop formation is produced at the rate of the beat frequency. The component droplets are formed at a period of 1/fH. Each recurring drop in the repeating pattern is formed at a period of |M/(M−N)|/fH or 1/fB and therefore corresponding recurring drops in the repeating pattern are separated by this period. The repeating pattern at the beat frequency may include forward and rearward merging satellites as well as satellite-free drops. This repeating pattern of drops of different character, herein called the controlled satellite sequence, allows selection of at least one recurring drop in the pattern that is most suitable for charge control and therefore for quality printing. It is advantageous to gutter the remaining droplets formed in the repeating pattern of the controlled satellite sequence, as they will be less than optimal in terms of satellite formation, merging behavior, and charge control.
The method of selecting one drop from the repeating pattern of the controlled satellite sequence effectively employs a print-selectable droplet generation rate that equals the beat frequency of the combined perturbation signal. The term “print-selectable drops” is used here to describe those drops in the controlled satellite sequence that have optimum character for accurately determining transferred charge and which are chosen on the basis of this drop quality to be available for printing. The term “print-selected drops” is used here to describe print-selectable drops that are used for printing, based on the data in the print data stream. In the present specification, drops may have one of two “selectability states”, namely that they are either print-selectable or they are not print selectable. In general there is a set of m sequential drops created during every period of the net cyclical perturbation, and the n-th drop in every set of m sequential drops has the same selectability state, wherein n=1,2,3 . . . m.
By way of example, equation (2) predicts that if M=4 and N=3, then fH=4/3fL and the beat frequency is fB=fH/4. This implies that a repeating pattern of four drops can be generated (each component drop of the pattern forming at a period 1/fH) and that with suitable choice of phase and amplitude of the component cyclical perturbation signals, at least one of the four drops in that sequence (each characteristic recurring drop formed with a period 4/fH) will be suitable for high reliability, high accuracy printing due to the favorable merging characteristics, or the absence of the satellites associated with that specific drop. If more than one drop in this sequence were selected for use in printing due to its favorable satellite formation characteristics, the print-selectable drop generation rate would lie between fH/4 and fH depending on the number of drops used. If k drops of the pattern were selected for printing then the effective print-selectable drop generation rate would be kfH/4. Corresponding print-selectable drops from consecutive periods of the net cyclical perturbation are separated by a period of 1/fB. The term “corresponding” is used here to describe the spatially sequential first print-selectable drop from the second and later periods, as “corresponding” to the spatially sequential first print-selectable drop of the first period. It is preferable to have a situation wherein there are no two print-selectable drops adjacent to each other within the linear sequence of drops. This minimizes the possibility of data-related crosstalk between print-selectable drops, which would otherwise occur via electrostatic induction.
It can further be shown that the droplet formation may be optimized by selection of the phase relationship and relative amplitudes of the lower frequency cyclical perturbation signal and the higher frequency cyclical perturbation signal such that a variety of satellite drop behaviors are evident in the pattern.
In like manner to the instance described above, it may be shown that, by using a suitable choice of relative amplitude and phase of the signals at frequencies fH and fL, droplets may be produced from the fluid jet at the lower frequency, fL, while the repeating pattern of satellite drop formation is produced at the rate of the beat frequency. The component droplets are formed at a period of 1/fL, whereas each recurring drop in the repeating pattern is formed at a period of |N/(M−N)|/fL. In a manner similar to that described above, this repeating pattern of drops of different character allows selection of at least one recurring drop in the pattern that is most suitable for charge control and therefore for quality printing. Comparing the two cases in which drop generation occurs at either at fH or fL it is noted that in the instance of the selection of a single print-selectable drop from each respective pattern arising from each case, that the print-selectable droplet generation rate equals the common beat frequency in each case, but that fewer drops are guttered in the case of drop generation at fL.
It may further be shown that the benefits of the control of satellite formation in the drop stream arising from the use of anharmonic stimulation are obtained with the use of at least two frequencies of non-harmonic relationship.
This invention is not only novel in employing an anharmonic stimulation signal to produce drops most suitable for printing, but also allows the charging sequence of a given guard drop scheme to be matched with the stimulation scheme.
Given that the use of a guard drop scheme implies that a subset of drops generated by a given nozzle would be guttered as non-printing drops, it is possible, by the use of the anharmonic stimulation scheme described herein, to select a combination of cyclical perturbation frequencies with associated integer multipliers, M and N, and the relative phase and amplitude of the cyclical perturbation signals, to ensure a match to the print-selectable drop sequence of a specific guard drop scheme.
A detailed description of preferred embodiments relating to the use of guard drop schemes in a two row array of nozzles follows.
For the sake of clarity, the present invention shall be described at the hand of a preferred embodiment in which all nozzles on linear inkjet nozzle array 1 may generate either neutral or positively charged inkjet fluid droplets. Conversely, all the nozzles on linear inkjet nozzle array 2 may generate either neutral or negatively charged inkjet fluid droplets. The charge on an inkjet fluid droplet is made neutral when the droplet is selected to print upon the printing medium. When an inkjet fluid droplet is selected for guttering, it is charged, the charge being positive for droplets emanating from linear inkjet nozzle array 1 and negative for droplets emanating from linear inkjet nozzle array 2. The means of charging inkjet fluid droplets in continuous inkjet printing systems are well documented in the prior art and shall not be further discussed herein.
Turning now to
The generation of drops by this scheme, creates, on each clock cycle, 2-dimensional sets of drops that move towards the surface to be printed upon. In principle, therefore, a plurality of continuous streams of liquid is perturbed into a plurality of linear sequences of drops. Drops from nearest neighbor nozzles to a given print-selectable nozzle, thereby constitute nearest neighbor drops to the drop from the print-selectable nozzle.
The linear repeat period of inkjet print head 3 for one guard drop charging scheme described in this particular embodiment has every third nozzle in the combined pattern from both linear inkjet nozzle array 1 and linear inkjet nozzle array 2 producing a neutral droplet. This may be most easily seen by considering the droplet charges produced at the same time by nozzles 11 to 16 and 21 to 26 in
In the forgoing sections, the interrelationship between the charging of the different nozzles in linear inkjet nozzle arrays 1 and 2 were explained for the case where example nozzle 22 was selected for printing and was therefore made neutral. On the next clock cycle of the drop generation frequency, the next nozzle selected for printing might be nozzle 12, followed by nozzle 23. When nozzle 12 is selected to print, droplets from nozzles 22 and 23 have to be negatively charged while droplets from nozzles 11 and 13 have to be positively charged. This is depicted by the second row of inkjet droplet charge states in
It is evident that the pattern may be repeated from this point onwards in cycles of three charge state selections. In this particular nozzle print sequence scheme, the droplets from nozzles 22, 12, 23, 13, 24, and 14 respectively have charge state sequences a, b, c, d, e, and f, and form a unit cell of charge states in the linear dimension delineated by lines 4 and 5 in
In another preferred embodiment of the invention the charge state sequence repeats in a pattern of 4 charge states, with every fourth drop emitted from a given nozzle being available for selection as a neutral printing drop. This cyclic arrangement of charge states in referred herein as a 1-in-4 or 1:4 guard drop scheme and is shown in
It is evident that the pattern may be repeated in time as well as linearly in cycles of four charge state selections. In this particular nozzle print sequence scheme, the droplets from nozzles 22, 12, 23, and 13, respectively have charge state sequences α, β, γ and δ, and form a unit cell of the arrangement a delineated in space by lines 4 and 6 in FIG. 4., and a repeating pattern of neutral printing drops at a period in the linear dimension of every four nozzles along both combined arrays (every two nozzles on either array). In respect of time, the charge state sequence of a particular nozzle repeats with every fourth droplet emitted by that nozzle. The permissible sequence of droplets bounded by lines 7 and 9 in
By way of example of the simultaneous use of anharmonic stimulation and the guard drop scheme, consider the case shown in
By way of further example, the 3-drop repeating pattern referred to above can also be produced by the choices N=2, and M-3 with suitable choice of phase and amplitude of those two frequency components.
Similarly in the case of
Alignment of the phase of the controlled satellite sequence produced by anharmonic frequency stimulation with the phase of the print selectable drops of the guard drop scheme requires multiple phases of stimulation delivered to the print head nozzles, as the guard drop schemes signals described are provided in multiple phases to the charge electrodes. Each stimulation electrode 30 surrounding each nozzle may be connected individually to a source of stimulation waveform. Alternatively, two or more stimulation electrodes may be connected together and to a common source of stimulation waveform. The benefit of the latter approach is that for arrays of large numbers of closely spaced nozzles, such as those found in high quality inkjet printing heads, accessing electrical connections to each individual stimulation electrode, through wire bonding for example, may be difficult given the small dimensions of the structures on the print head. Connecting multiple nozzles through conductive traces connected to one connection point allows a larger distance between electrical connection points thereby increasing accessibility.
As a further extension of the present invention, it is possible to have not only the primary lower frequency fL and the primary higher frequency fH, but at least one additional cyclical perturbation signal having frequency anharmonically related to fL and fH. The adjustment of the phase and amplitude of the additional anharmonic perturbation signal allows the forwards and backwards merging of satellite drops to be controlled for those drops that are not optimal printing drops by virtue of the primary beat frequency. This allows a further degree of control over the quality of drops formed in the system.
In a more general implementation of the present invention, any number of further anharmonic perturbation signals may be applied in order to manipulate drop formation and satellite drop formation by the mechanism described here.
There have thus been outlined the important features of the invention in order that it may be better understood, and in order that the present contribution to the art may be better appreciated. Those skilled in the art will appreciate that the conception on which this disclosure is based may readily be utilized as a basis for the design of other methods and apparatus for carrying out the several purposes of the invention. It is most important, therefore, that this disclosure be regarded as including such equivalent methods and apparatus as do not depart from the spirit and scope of the invention.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4047183 | Taub | Sep 1977 | A |
| 4070679 | Fan et al. | Jan 1978 | A |
| 4734705 | Rezanka et al. | Mar 1988 | A |
| 6070973 | Sachs et al. | Jun 2000 | A |
| 6224180 | Pham-Van-Diep et al. | May 2001 | B1 |
| Number | Date | Country |
|---|---|---|
| 58201662 | Nov 1983 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20050185031 A1 | Aug 2005 | US |
