The present invention relates to droplet deposition apparatus. It may find particularly beneficial application in a drop-on-demand ink-jet printhead, or, more generally, in droplet deposition apparatus and, specifically, in droplet deposition apparatus comprising: an array of fluid chambers, each chamber being provided with a nozzle and at least one piezoelectric actuator element operable to cause the release, on demand, of a droplet of fluid from the chamber through the nozzle, the array extending in an array direction; a common inlet manifold extending substantially the length of said array and being elongate in said array direction, for supplying fluid to said array of chambers; and a common outlet manifold extending substantially the length of said array and being elongate in said array direction, for receiving fluid from said array of chambers.
Those skilled in the art will appreciate that a variety of alternative fluids may be deposited by droplet deposition apparatus: droplets of ink may travel to, for example, a paper or other media, such as ceramic tiling, to form an image, as is the case in inkjet printing applications; alternatively, droplets of fluid may be used to build structures, for example electrically active fluids may be deposited onto media such as a circuit board so as to enable prototyping of electrical devices, or polymer containing fluids or molten polymer may be deposited in successive layers so as to produce a prototype model of an object (as in 3D printing). Droplet deposition apparatus suitable for such alternative fluids may be provided with modules that are similar in construction to standard inkjet printheads, with some adaptations made to handle the specific fluid in question.
In addition, a wide variety of constructions exist within the prior art for droplet deposition, including a number that have been disclosed by the present Applicant. Of particular interest in the present case are the examples provided by WO 00/38928, from which
WO 00/38928 provides a number of examples of droplet deposition apparatus having an array of fluid chambers, with each chamber communicating with an orifice for droplet ejection, with a common fluid inlet manifold and with a common fluid outlet manifold and where there is, during use, a fluid flow into the inlet manifold, through each chamber in the array and into the outlet manifold.
More particularly, as taught in EP-A-0 277 703 and EP-A-0 278 590, piezoelectric actuator walls may be formed between successive channels and are actuated by means of electric fields applied between electrodes on opposite sides of each wall so as to deflect transversely in shear mode. The resulting pressure waves generated in the ink or other fluid cause ejection of a droplet from the nozzle.
To simplify manufacture and increase yield, the “pagewide” row(s) of nozzles may be made up of a number of modules, one of which is shown at 40, each module having associated fluid chambers and actuation means and being connected to associated drive circuitry (integrated circuit (“chip”) 50) by means e.g. of a flexible circuit 60. Ink supply to and from the printhead is via respective bores (not shown) in end-caps 90.
WO 00/38928 teaches that ink may be fed into an inlet manifold and out of an outlet manifold, with the manifolds being common to and connected via each channel, so as to generate ink flow through each channel (and thus past each nozzle) during printhead operation. This may act to prevent the accumulation of dust, dried ink or other foreign bodies in the nozzle that would otherwise inhibit ink droplet ejection.
In more detail, ink enters the printhead of
Each row of chambers 300 and 310 has associated therewith respective drive circuits 360,370. The drive circuits are mounted in substantial thermal contact with that part of structure 200 acting as a conduit and which defines the ink flow passageways so as to allow a substantial amount of the heat generated by the circuits during their operation to transfer via the conduit structure to the ink. To this end, the structure 200 is made of a material having good thermal conduction properties. WO 00/38928 teaches that aluminum is a particularly preferred material, on the grounds that it can be easily and cheaply formed by extrusion. Circuits 360,370 are then positioned on the outside surface of the structure 200 so as to lie in thermal contact with the structure, thermally conductive pads or adhesive being optionally employed to reduce resistance to heat transfer between circuit and structure.
Further detail of the chambers and nozzles of the particular printhead shown in
A break in the electrodes at 810 allows the channel walls in either half of the channel to be operated independently by means of electrical signals applied via electrical inputs (flexible circuits 60). Ink ejection from each channel half is via openings 840,850 that communicate the channel with the opposite surface of the piezoelectric base component to that in which the channel is formed. Nozzles 870,880 for ink ejection are subsequently formed in a nozzle plate 890 attached to the piezoelectric component.
The large arrows in
As a result, it will be appreciated that there is, during use of the printhead, a flow of fluid along the length of each of the chambers 600,610. As noted above, WO 00/38928 teaches that this ink flow through each channel (and thus past each nozzle) during printhead operation may act to prevent the accumulation of dust, dried ink or other foreign bodies in the nozzle that would otherwise inhibit ink droplet ejection. More, WO 00/38928 teaches that, to ensure effective cleaning of the chambers by the circulating ink and in particular to ensure that any foreign bodies in the ink, e. g. dirt particles, are likely to go past a nozzle rather than into it, the ink flow rate through a chamber must be higher than the maximum rate of ink ejection from the chamber and may, in some cases, be ten times that rate.
In more detail,
Substrate 86 is formed with conductive tracks 192, which are electrically connected to the respective channel wall electrodes, (for example by solder bonds), and which extend to the edge of the substrate (86) where respective drive circuitry (integrated circuits 84) for each row of channels is located.
As may also be seen from
As with the construction described with reference to
As may be seen in
In droplet deposition apparatus it is generally desirable to improve the uniformity over the length of the array of the droplets deposited; this is particularly the case with droplet deposition apparatus that have a large array of fluid chambers, such as inkjet printers. Where media is indexed past the array of fluid chambers to produce a pattern of droplets on the media (for example forming an image on a sheet of paper or a ceramic tile) such non-uniformity over the length of the array may be particularly visible, since it will produce generally linear defects extending in the direction of substrate movement, the human eye being particularly adept at identifying such linear features.
However, even where the pattern formed is not intended to be viewed by the human eye (such as where electrically active fluids are deposited onto media such as a circuit board so as to enable prototyping of electrical devices, or polymer containing fluids or molten polymer may be deposited in successive layers so as to produce a prototype model (so-called 3D printing)), or where the media is not indexed past the array, it will still be appreciated that non-uniformity over the length of the array will be a concern.
There are numerous factors that are thought to cause non-uniformity of deposited droplets, with the interactions between these factors complex and often difficult to predict. Embodiments of the present invention may therefore exhibit improved uniformity in droplet deposition over the array of fluid chambers. However, it should be noted that further and/or other advantages may stem from embodiments of the present invention.
Thus, in accordance with a first aspect of the present invention there is provided droplet deposition apparatus comprising: an array of fluid chambers, each chamber being provided with a nozzle and at least one piezoelectric actuator element operable to cause the release, on demand, of a droplet of fluid from the chamber through the nozzle in an ejection direction, the array extending in an array direction, substantially perpendicular to said ejection direction; a common inlet manifold extending at least substantially the length of said array and being elongate in said array direction, for supplying fluid to said array of chambers; a common outlet manifold extending at least substantially the length of said array and being elongate in said array direction, for receiving fluid from said array of chambers; and a first flow restrictor passage connecting said array of chambers to one of said common inlet manifold and said common outlet manifold, so as to enable, respectively: a flow of fluid during use of the apparatus along the length of said common inlet manifold, through said first flow restrictor passage, then through said array of fluid chambers, and then into and along the length of said common outlet manifold; or a flow of fluid during use of the apparatus along the length of said common inlet manifold, through said array of fluid chambers, then through said first flow restrictor passage, and then into and along the length of said common outlet manifold; wherein said first flow restrictor passage extends substantially the length of said array in said array direction;
wherein said one of the common inlet manifold and the common outlet manifold, and said first flow restrictor passage are shaped such that said first flow restrictor passage appears as a narrow, elongate passage leading from or to respectively said one of the common inlet manifold and the common outlet manifold, when viewed in cross-section perpendicular to the array direction; and
wherein said first flow restrictor passage presents sufficient impedance to fluid flow such that, in use, fluid within said first flow restrictor passage adjacent said array of chambers is directed generally perpendicular to said array direction for substantially all the chambers within the array.
The Applicant has identified variation in flow distribution over the length of the array as being a factor that may have a significant effect upon the uniformity of the droplets deposited by the array. More particularly, in apparatus where there is a common inlet manifold extending substantially the length of said array and being elongate in said array direction, for supplying fluid to said array of chambers and a common outlet manifold extending substantially the length of said array and being elongate in said array direction, for receiving fluid from said array of chambers, the flow of fluid within such common manifolds will generally be parallel to the array direction. However, if the flow adjacent the array of fluid chambers is also generally parallel to the array direction, the distribution of the flow over the chambers within the array may be poor. Measures have therefore been taken in prior art constructions to alter the direction of the flow adjacent to the array of chambers so that it is closer to perpendicular to the array direction.
For example, as noted above, WO 00/38928 provides arrays of ports 88, 90, 92 that assist in changing the direction of the flow from one generally parallel to the nozzle row, or array direction, to one generally perpendicular to the array direction and therefore directed along the lengths of the fluid chambers. However, drawbacks exist with such constructions; in particular, the chambers closest to the ports 88, 90, 92 are found to generally receive relatively more flow, whereas the chambers more distant to the ports 88, 90, 92 are found to generally receive relatively less flow. In addition, the flow distribution may be relatively sensitive to variations in the size and/or shape of the ports 88, 90, 92. Further, the overall construction may be relatively complex and costly to produce, involving a number of separate components that must be assembled.
Other approaches are disclosed in WO 2005/007415, also belonging to the present Applicant. Specifically, a construction is disclosed where inlet and outlet plenum chambers are provided on either side of an array of ejection chambers spaced in an array direction. The inlet manifold, which extends in the array direction, communicates with the inlet plenum chamber through a porous sheet. Similarly, the outlet plenum chamber communicates with the outlet manifold, which also extends in the array direction, through the same porous sheet. In use of the apparatus there is a flow of fluid between the inlet manifold and the outlet manifold through the chambers. The porous element is designed, for example by the use of a sintered ceramic material, to provide the dominant pressure drop in this flow. As a result, whilst there may be substantial net ink flows in the array direction in the inlet and the outlet manifolds, the document suggests that there is substantially no net flow in the array direction in the inlet or outlet plenum chamber.
However, drawbacks exist with such constructions also. More particularly, the large pressure drop across the porous element may cause the apparatus to present a large overall impedance to fluid flow, which may necessitate the use of complex and costly fluid supply systems. Specifically, it has been found the pressure differential required to provide desirable flow rates through such constructions (which may act to prevent the accumulation of dust, dried ink or other foreign bodies in the nozzle that would otherwise inhibit droplet deposition, as taught by WO 00/38928) may be so large that gravity-based fluid supply systems, where the pressure differential is provided by suitable differentials in height between fluid reservoirs and the array of nozzles, are no longer practical. For example, the height differential required may be several metres, or more, thus making the overall size of the apparatus unacceptably large. Further, the porous sheet, or other porous elements taught by the document may progressively and irreversibly block up with particles suspended within the fluid (for example, in the case of ink, pigment particles), with these particles becoming lodged within and on the surfaces of the porous element. Furthermore, the overall construction may be relatively complex and costly to produce, involving a number of separate components that must be assembled. In particular, providing a porous element that is sufficiently robust and homogenous may be challenging in practice. In addition, it may be difficult to form the plenum chambers taught by WO 2005/007415.
According to the present invention, the first flow restrictor passage presents sufficient impedance to fluid flow such that, in use, fluid within the first flow restrictor passage adjacent said array of chambers is directed generally perpendicular to the array direction at substantially all the chambers within the array. As the first flow restrictor passage extends substantially the length of said array in said array direction, there may be less local variation in flow rates, as compared to the constructions disclosed in WO 00/38928, where ports are utilised. Further, manufacturing a passage and specifically a passage that extends substantially the length of the chamber array may be relatively straightforward (for example by machining or moulding components). More generally, manufacturing apparatus according to the present invention may involve the assembly of fewer and/or less costly components.
In embodiments, the flow restrictor passage may described as being connected directly to both the array of fluid chambers and one of the common inlet manifold and the common outlet manifold. Hence, or otherwise, one end of the flow restrictor passage may open into said of the common inlet manifold and the common outlet manifold, while the other end of the flow restrictor passage may open into the array of fluid chambers. In embodiments of the invention, the flow restrictor passage may have the same cross-section for substantially its whole length in the array direction. Such embodiments may be particularly straightforward to manufacture and may provide particularly consistent behaviour over its length in the array direction in terms of modifying fluid flow.
The Applicant considers that the principles discussed above with regard to the flow restrictor passage may also be applied in apparatus not necessarily provided with an outlet manifold. Therefore, according to a further aspect of the invention there is provided a droplet deposition apparatus comprising: an array of fluid chambers, each chamber being provided with a nozzle and at least one piezoelectric actuator element operable to cause the release, on demand, of a droplet of fluid from the chamber through the nozzle in an ejection direction, the array extending in an array direction, substantially perpendicular to said ejection direction; a common inlet manifold for supplying fluid to said array of chambers, the common inlet manifold extending substantially the length of said array and being elongate in said array direction, so as to enable a flow of fluid during use of the apparatus along the length of said common inlet manifold; and a flow restrictor passage connecting said common inlet manifold to said array of chambers, the first flow restrictor passage extending substantially the length of said array in said array direction; wherein said common inlet manifold and said first flow restrictor passage are shaped such that said first flow restrictor passage appears as a narrow, elongate passage leading from the common inlet manifold, when viewed in cross-section perpendicular to the array direction; and wherein said first flow restrictor presents sufficient impedance to fluid flow such that, in use, fluid within said first flow restrictor adjacent said array of chambers is directed generally perpendicular to said array direction for substantially all the chambers within the array.
The present invention will now be described with reference to the accompanying drawings, in which:
The present invention may be embodied in a printhead and, more specifically, an inkjet printhead.
As may be seen from
On opposite channel-facing surfaces of the piezoelectric walls are arranged electrodes to which voltages can be applied via connections provided on the side surfaces (34) of the substrate member (86). These side surfaces may be seen more clearly in
As is also shown by
The electrical connections on the side surfaces (34) of the substrate member (86) are provided by conductive tracks (192), which lead to integrated drive circuitry (84) disposed towards the top of the side surface (34). A flexible connector extends away from the drive circuitry (84), as is shown in
As is also visible in
As is shown in
Further details of the manifold chambers will be apparent from
In addition, there is displayed an inlet flow restrictor (28) passage that links the inlet manifold chamber (18) to the array of fluid chambers (14). A similar, outlet flow restrictor (32) passage is also indicated in the drawing and links the array of chambers (14) to the outlet manifold chamber (19). Both of these flow restrictor passages extend the length of the array of fluid chambers (14) and, as may be seen from the drawing, when a cross-section taken perpendicular to the array direction (100) is considered, they are relatively narrow in comparison to the manifold chambers and have an elongate cross-sectional shape. As may also be seen from the drawing, the inlet flow restrictor passage (28) is connected to one longitudinal end of each of the chambers in the array (14) and the outlet flow restrictor passage (32) is connected to the other longitudinal end of each of the chambers in the array (14).
In the specific embodiment shown in
The purpose of the flow restrictor passages may be better understood with the aid of
As may be seen, there is a flow along the length of the inlet manifold chamber (18), in a direction into the page in the view of
As may also be seen, while the flow (21, 22) in the inlet and outlet manifold chambers (19,18) is generally parallel to the array direction (100), the flow (23, 24) in the flow restrictor passages is generally perpendicular to the array direction (100). This is achieved by designing the flow restrictor passages so as to provide suitable impedance to fluid flow between the respective one of the inlet and outlet manifold chambers (19,18) and the array of fluid chambers (14). The effect of this impedance is to “turn” the direction of fluid flow from one that is parallel to the array direction (100) to one that is perpendicular to the array direction (100). More particularly, the impedance is such that the fluid flow is perpendicular to the array direction (100) for substantially all the chambers within the array.
The overall flow path is therefore from the inlet manifold chamber (18), generally in a direction parallel to the array direction (100), then into the inlet flow restrictor (28), generally in a direction perpendicular to the array direction (100), then into the fluid chambers, generally in the chamber extensions direction. Fluid in excess of that required for droplet deposition then flows to the outlet flow restrictor (32) in a direction generally perpendicular to the array direction (100), before emerging into the outlet manifold chamber (19), where it returns to flowing generally in a direction parallel to the array direction (100), though in the opposite direction to the flow (21) in the inlet manifold chamber (18).
In the embodiment shown in
On the other hand, it should be noted that protrusions or baffles within the flow restrictor passages may also be utilised to distribute the flow and/or alter the impedance of the flow restrictor passages.
The impedance necessary to achieve the particular flow patterns described above may vary depending on the particular construction of the droplet deposition apparatus. However, the general design considerations will typically be similar and will now be described with reference to
As may be seen from the diagram, the effect of the inlet flow restrictor (28) is to cause fluid, which flows generally in the array direction (100) along the length of the inlet manifold chamber (18), to “turn” and be directed perpendicular to the array direction (100) as it approaches the array of fluid chambers (14). In the specific embodiment depicted in
As will be apparent from the streamlines visible in the dashed boxes of
Thus, in order to ensure that fluid within the flow restrictor passage (28) adjacent the array of chambers is generally evenly distributed for substantially all the chambers within the array (14), it may be appropriate to utilise a flow restrictor passage with a width of less than 700 microns. At this width, the ratio of the impedance over the length of the flow restrictor passage to the impedance over the length of the inlet manifold chamber (18) is approximately 1:85. Thus, even with a flow restrictor passage that provides a surprisingly small amount of impedance, there may be a beneficial effect in terms of modifying the direction of the fluid flow adjacent the array of fluid chambers (14).
It should further be appreciated that the pressure drop over the flow restrictor passage is even smaller in comparison to the pressure drop across the array of fluid chambers (14). For the passage of 700 microns width, the ratio is approximately only 1:450. Thus the impedance of the flow restrictor is considerably less than that of the actuator. This may be contrasted with constructions disclosed in WO 2005/007415, where the porous element provides the dominant pressure drop in a flow of fluid between the inlet manifold and the outlet manifold through an array of fluid chambers (14).
For narrower flow restrictor passages (and therefore higher impedances) modeling tests indicate that the flow within the flow restrictor passage will begin to transition from laminar flow to turbulent flow. More particularly, modeling tests suggest that this transition begins to occur with passages having a width of less than 175 microns. This corresponds to a ratio for the impedance over the length of the flow restrictor passage to the impedance over the length of the inlet manifold chamber (18) of around 4:3, or an absolute impedance for the flow restrictor of 716 MPa/m3s−1.
It should further be appreciated that, even with the relatively higher impedance of this flow restrictor passage, the pressure drop over the flow restrictor passage is nonetheless considerably smaller in comparison to the pressure drop across the array of fluid chambers. For the passage of 175 microns width, the ratio is still approximately only 1:15. Thus the impedance of the flow restrictor is still considerably less than that of the actuator. Again, this may be contrasted with constructions disclosed in WO 2005/007415, where the porous element provides the dominant pressure drop in a flow of fluid between the inlet manifold and the outlet manifold through an array of fluid chambers. Thus, providing a suitable fluid supply for apparatus according to embodiments of the present invention may be significantly easier.
More generally, while in the embodiments discussed with reference to
Thus, providing such a flow restrictor passage where the impedance is greater than 42 MPa/m3s−1 and/or less than 716 MPa/m3s−1 may be generally advantageous in terms of flow properties where such geometry is present, for the reasons discussed above. Similarly, providing a flow restrictor passage where the ratio of the impedance over its length to the impedance over the length of the manifold chamber is greater than 1:85 and/or less than 4:3 may also be advantageous more generally in embodiments with such geometry.
Further, it should be noted that, as briefly discussed above, protrusions or baffles may be provided within flow restrictor passages to achieve such impedances and/or pressure drops. In addition, rather than varying the width of the flow restrictor passage, the length and, more generally, the shape of the flow restrictor passage may be altered instead. In particular, serpentine, or curved paths for the flow restrictor passage may be utilised, or ribs or ridges may be provided adjacent the flow restrictor passage, defining the shape of the passage.
Further details of the manifold chambers of the printhead of
As may also be seen, both the manifold chambers (18, 19) are tapered with respect to the array direction (100), though in opposite senses. This assists in ensuring that the same rate of flow is provided for all chambers within the array (14). In an optional modification, one or both of the flow restrictor passages (28, 32) might be tapered instead, or in addition.
In addition, providing a taper within the manifold chambers (18, 19) may assist with purging of the fluid chambers as part of a start-up mode for the apparatus. For example, the taper may ensure a roughly equal amount of fluid flow passes through each of the chambers in the array. This may, for example, reduce the likelihood of bubbles being trapped at the end of the array furthest from the point where enters the manifold.
During use of the printhead shown in
It will be appreciated that, while in the embodiment of
While the foregoing embodiments have made use of an actuator block where piezoelectric actuator elements are provided by elongate piezoelectric wall elements that separate successive elongate channels, it will be understood that the present invention may be applied more broadly. Specifically, a variety of piezoelectric actuator elements may be utilised, such as those formed using thin-film techniques (for example, sol gel, or vapour deposition) and incorporated in a MEMS device. In more detail, such thin-film techniques may be utilised to provide an array of piezoelectric actuator elements on the edge surface of the substrate member, though it will of course be appreciated that this particular geometry is by no means essential for implementing the present invention in a MEMS device. As in embodiments discussed above with reference to the figures, thin-film piezoelectric actuator elements may be electrically connected to drive circuitry using interconnector tracks provided on the side surfaces of the substrate member.
It will be understood that, particularly with such elements, it is not necessary for the piezoelectric actuator elements to form a wall of the corresponding fluid chamber.
For example, diaphragm-type piezoelectric actuators may be utilised, which each include a body of piezoelectric material mounted on a diaphragm member that bounds a portion of a corresponding one of the fluid chambers. The body of piezoelectric material is then actuable in response to electrical signals to cause the deformation of said diaphragm member so as to vary the volume of said corresponding one of the fluid chambers. The diaphragm member may be generally planar and may be supported around a portion of, or substantially all of, a perimeter, while being substantially unsupported within said perimeter. In some constructions the diaphragm member will also bound a further chamber, in which the body of piezoelectric material is located.
While the foregoing embodiments have included only one array of fluid chambers with a single inlet manifold chamber and a single outlet manifold chamber, it should be appreciated that the present invention may be embodied in constructions having several arrays of fluid chambers. In such embodiments, multiple inlet and/or outlet manifold chambers may be provided; according to the present invention, a flow restrictor passage connects one of these arrays of chambers to one of the inlet manifold and/or outlet manifolds.
For example, in a similar manner to the prior art constructions described with reference to
It should further be appreciated that the principles discussed above with regard to the flow restrictor passages may also be applied to apparatus having only an inlet manifold (so that there is no outlet manifold). In such embodiments, the flow restrictor passage will nonetheless present sufficient impedance to fluid flow such that, in use, fluid within the flow restrictor adjacent the array of chambers is directed generally perpendicular to the array direction for substantially all the chambers within the array.
Further, while the foregoing embodiments have concerned an inkjet printhead, as noted above, a variety of alternative fluids may be deposited by droplet deposition apparatus. Thus, where reference is made above to an inkjet printhead this should be understood only as giving a particular example of a droplet deposition apparatus.
Number | Date | Country | Kind |
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1411842.6 | Jul 2014 | GB | national |
Filing Document | Filing Date | Country | Kind |
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PCT/GB2015/051940 | 7/2/2015 | WO | 00 |