The present invention relates to printing apparatus, and more particularly to apparatus which prints using projection of droplets of liquid. The invention also relates to a method of printing.
In a known type of printing apparatus, namely inkjet printers, the printed image is created by firing discrete droplets of ink from a drop firing chamber onto the surface to be printed. The throughput time of an inkjet printer is restricted by the time taken to refill the droplet firing chamber before the next droplet can be emitted.
The present invention provides printing apparatus comprising a rotatable member, drive means for rotating the member, liquid feeding means for feeding liquid to the member to form droplets of the liquid thereon, droplet release means for causing droplets to be released selectively from the member as it rotates, such that the droplets are projected towards a substrate spaced from the member, and control means for controlling the droplet release means to form a predetermined pattern of droplets on the substrate.
The apparatus of the invention enables the generation of droplets at a high rate, facilitating high throughput.
It will be appreciated that most of the kinetic energy needed to project the drop onto the substrate can be derived from the rotation of the rotatable member. Thus a drop to be released from the member will already have most of the kinetic energy it needs to be projected onto the substrate before it is released, so that the droplet does not need to undergo the rapid linear acceleration and changes of acceleration to which a drop being ejected from a conventional inkjet printing head is subjected.
Control of the rotation of the member can ensure substantially constant initial droplet velocity (since any velocity imparted by the droplet release means may be small relative to the velocity of the rotatable member), and helps to ensure that initial drop velocity is substantially immune to variations in the temperature of the ink, ink composition or environmental parameters (for example air temperature, pressure, humidity etc.).
The system also enables relatively small drop sizes to be used and for high initial drop velocities to be achieved. In addition, the detached drop will have a much lower internal kinetic energy than a drop fired from the head of a forced ejection system. In addition, problems of jet-created ligatures or satellite droplets can be reduced or avoided, and higher polymer weight inks may be used as the release of a droplet from the member can involve a relatively low energy change in the former.
An apparatus according to the invention may also be advantageously incorporated in a system in which ink is transferred to an intermediate substrate and then, in turn, onto the substrate to be printed.
In an existing type of such printing apparatus a continuous layer of ink is deposited onto a first cylinder. A second cylinder with an engraved surface is then brought into contact with the first cylinder so that ink is transferred from the coated first cylinder onto the second cylinder. The second cylinder is subsequently rolled over the surface to be printed, creating the desired image thereon.
The transfer of ink from the first cylinder to the second is accomplished by bringing the cylinders close together so that the ink is transferred without forming discrete droplets. This requires that the surface velocities of the rotating cylinders are carefully matched. According to the present invention, printing may be achieved via an intermediate cylindrical surface by spacing the rotatable member from the intermediate surface. This enables the speed of rotation of the rotatable member to be controlled independently to that of the intermediate surface to achieve the desired velocity and frequency of droplet ejection therefrom.
In a preferred embodiment, the rotatable member is in the form of a cylinder. The cylinder is rotatable about its longitudinal axis, and the liquid feeding means is arranged to feed liquid to its circumferential surface.
The droplets may be formed on the member by the liquid feeding means at a predetermined array of droplet sites. The droplets are preferably formed in an array extending across the member in the longitudinal direction, so that droplets can be generated simultaneously in several locations.
The liquid feeding means may be arranged to replace droplets released from the rotatable member, thereby maintaining a supply of droplets for subsequent release from the member.
The droplet release means may comprise means for selecting droplets for subsequent release. According to one preferred embodiment, the droplet selecting means comprise a respective radiation detector for each droplet site, and a radiation source for selectively irradiating the detectors to select droplets to be released.
This selection serves to “prime” the selected sites for subsequent release of the respective droplets by the droplet release means. A trigger may be provided, along with means responsive to the trigger associated with each droplet site. As droplet sites reach a given point in their cycle of rotation on the rotatable member, the trigger is arranged to interact with the responsive means associated with primed droplet sites causing the release of the corresponding droplets.
Preferably, the responsive means is a phototransistor, and the trigger is a radiation source to which the phototransistor is responsive. The radiation source may be an LED array for example.
The ability to de-couple the drop selection process from the release process is technically beneficial, because one may require spatial precision and the other high power. Power and spatial precision together may be more difficult to achieve than separately.
Preferably, the droplet release means comprise a radiation source for irradiating the location of selected droplets. This radiation may serve to raise the temperature of the selected droplets, reducing their adherence to the member sufficiently for them to be released from the member.
Energy from the radiation source may be absorbed by the droplets. The droplets may be substantially transparent with respect to the radiation. In a preferred implementation, the energy is absorbed by the member below the respective droplet instead of, or as well as by the droplets. The temperature of the surface of the rotatable member below the selected droplet is thereby increased, heating the droplet sufficiently to cause its release.
In a further embodiment, the energy from the radiation source increases the viscosity of the selected droplets causing them to be released from the member. For example, the droplet liquid may comprise a photoreactive chemical, such as a UV curable material. The radiation is selected such that it cures an irradiated droplet into a solid or semi-solid state, thereby reducing the strength of its adhesion to the member and causing its release therefrom.
The droplet release means may comprise a respective droplet heater for each droplet site, a predetermined increase in the temperature of each heater causing the respective droplets to be released. The heater may comprise an electrically resistive element, for example.
The droplet release means may comprise means for electrostatically charging selected droplets, and means for creating an electric field to release the selected droplets.
In a further embodiment, the droplet release means comprise a respective mechanical actuator for each droplet site movable to release the respective droplet from the member. Each activator may be operated by a respective piezoelectric device. Alternatively, each actuator may comprise electrostatically deflectable material, and the droplet release means comprise means for generating an electric field to operate the respective actuator.
In another preferred variation in accordance with the invention, the droplet release means comprise means for creating a high voltage field to induce an electrostatic moment in selected droplets causing the selected droplets to be released from the member.
To encourage formation of discrete, well defined droplets on the surface of the rotatable member, the surface material of the member surrounding the droplet sites may repel the droplet liquid material.
Preferably, the liquid feeding means defines an opening, such that in use the liquid forms a meniscus at the opening which protrudes beyond the opening and contacts the rotatable member. Alternatively, the liquid feeding means may comprise absorbent material in contact with a supply of liquid, and also in contact with the rotatable member.
In a preferred embodiment, means are provided for absorbing some or all of the liquid from a droplet which was not released from the surface of the rotatable member. The composition of droplets remaining on the surface of the rotatable member may change over time, owing to evaporation for example. In the case of liquid ink, the solvent used in pigmented dispersions will often evaporate, thereby increasing the pigment concentration in the droplets which may be undesirable. The droplet absorbing means allows maintenance of the composition and/or volume of the droplets by enabling replacement of liquid of droplets carried by the cylinder with “fresh” liquid from a reservoir. In a preferred embodiment of this configuration, the liquid feeding means provides the droplet absorbing means.
In arrangements where the liquid feeding means forms a meniscus contacting the cylinder, as the meniscus cones into contact with a droplet, liquid absorbed from the droplet and as the droplet site moves away from the meniscus a new droplet is formed using “fresh” liquid drawn from the chamber.
The droplet absorbing means may be operable to feed absorbed droplets into a reservoir of liquid from which liquid is drawn for feeding onto the rotatable member.
In an embodiment where the liquid feeding means provides the droplet absorbing means, the liquid feeding means may comprise a chamber having an inlet and an outlet connected to a reservoir means, and means for circulating liquid between the chamber and the reservoir means.
The present invention further provides a method of printing comprising the steps of rotating a rotatable member, feeding liquid to the surface of the member to form droplets thereon, and causing droplets to be released selectively from the member, such that the droplets are projected towards a substrate spaced from the member to form a predetermined pattern of droplets on the substrate.
Embodiments of the invention will now be described by way of example and with reference to the accompanying schematic drawings wherein:
a) shows a perspective view of a rotatable cylinder for use in the apparatus of
b) shows an enlarged cross-sectional side view of part of the cylinder of
a) shows a perspective view of liquid feeding means for use in the apparatus of
b) and 3(c) show further embodiments of liquid feeding means for use in the apparatus of
d) shows an embodiment of liquid feeding means in combination with droplet absorbing means for use in the apparatus of
a) to 6(f) show features of droplet release means according to a fourth embodiment of the invention; and
It should be noted that the Figures are diagrammatic and not drawn to scale. Relative dimensions and proportions of these Figures have been shown exaggerated or reduced in size, for the sake of clarity and convenience in the drawings. The same reference signs are generally used to refer to corresponding or similar features in modified and different embodiments.
The printing apparatus of
Typically, the droplets may have a diameter of less than 300 microns—40 microns for example—and a volume less than 500 pL-20 pL for example.
Droplet release means 32 cause selected droplets to be released from the cylinder, as will be described in more detail below. Control means 34 monitor rotation of the cylinder via an electrical connection 3b to an appropriately located sensor, in the drive means 16, for example, and control operation of the droplet release means 32 via a further electrical connection 38.
A released droplet 18′ is shown in
a) shows a cylinder 10 having an array of droplet forming sites mutually spaced apart over the circumferential surface of the cylinder. The disc-shaped sites have a diameter or around 30 microns, and are spaced around 10 microns apart in the axial direction and around 200 to 300 microns apart in the circumferential direction on the cylinder surface. The cylinder may have a radius less than 4 cm, typically around 5 to 6 mm and an axial length of 300 mm, for example.
In use, the cylinder may rotate with a surface angular acceleration of over 10 m/s/s, typically of the order of 68,000 m/s/s. This corresponds to a cylinder with a radius of 6 mm rotating at approximately 32,000 revolutions per minute. Under these conditions, a released droplet may travel with an initial speed of around 20 m/s.
b) illustrates a cross-section of cylinder 10 having two types of surface material coating: a hydrophobic coating 214 that repels liquid 26 and a hydrophilic coating 213 that attracts liquid 26. The hydrophobic surface areas 214 may be formed from a hydrophobic silane coating, for example a silane, siloxane or trichlorosilane treated substrate 212 of quartz, glass or ceramic material. The hydrophilic surface areas 213 may be formed from a metal, for example a 1 micron thick layer of gold, tantalum or molybdenum and which will also not bind chemically with the hydrophobic surface treatment. A hydrophobic additive to the liquid 26 may be used to renew the hydrophobic coating on the hydrophobic areas of the surface 211 without affecting the hydrophilic behaviour of the hydrophilic surface areas 213.
The liquid feeding means of
Channel 205 may be 100 mm long and 300 microns wide, for example, and positioned 200 microns from the surface of cylinder 10. The channel may typically be defined by edges of two opposing plates.
The liquid feeding means of
Ink that has traveled around the cylinder as a surface droplet is mixed with ink from the chamber 204 and recirculated to the ink reservoir 24, maintaining a substantially consistent formulation of liquid droplets on the surface of the rotating cylinder.
In
d) shows an arrangement similar to those of
A flexible member 243 is provided on the ink absorbing chamber 233 adjacent to the channel 239 which has a distal edge close to or in contact with the surface of cylinder 10. Member 243 serves to prevent formation of droplets by the meniscus 241, ensuring that absorbed ink is recirculated instead. The absorbed ink is fed from ink absorbing chamber back to the reservoir via an outlet tube 245.
A preferred embodiment of a printing apparatus including the liquid feeding means of
A further example of droplet release means of the invention is shown in
a) to (f) illustrate another preferred embodiment of droplet release means according to the invention. Referring firstly to the circuit diagram of
As shown in
c) shows an enlarged cross-sectional side view of the cylinder 10 of
Each droplet site has an associated light responsive phototransistor circuit, as shown in
After drop ejection, the charge at connection 433 (see
An example of the distribution of an array of droplet sites 202 with associated phototransistor sites 412 is shown in
f) shows a cross-sectional side view of a cylinder incorporating the phototransistor circuit of
The surface of the cylinder comprises a protective layer 429, which is formed of transparent material, for example fused silica, over the phototransistor and photoconductor components (not shown) associated with the droplet sites. The layer 429 is treated with a hydrophobic coating 430 which encourages liquid droplets 18 to form preferentially on the relatively hydrophilic material of the droplet site 202 (for example, tantalum or molybdenum) when the cylinder is wetted with a hydrogen bonding liquid, for example a water based ink.
The released droplets may land directly onto the surface to be printed. Alternatively, they may land on an intermediate printing surface, such as a roller, which is in contact with or subsequently moved into contact with the surface to be printed. A continuously variable image or pattern can thus be formed on the printed surface.
The droplet liquid material may be ink or paint, for example. It will be appreciated that a range of other liquids may be used, such as conductive, semi-conductive, insulative or photoresist materials used in the fabrication of printed electronic circuits; or liquids containing polymers, for example electropolymers.
Number | Date | Country | Kind |
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0417915.6 | Aug 2004 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB05/02964 | 7/25/2005 | WO | 00 | 7/27/2007 |