Patent Application
20120147105
The apparatus and method described below relates to devices for heating phase change ink, and more particularly to using immersed heaters in an ink reservoir to melt solidified ink.
Inkjet printers eject drops of liquid ink from inkjet ejectors to form an image on an image receiving surface, such as an intermediate transfer surface, or a media substrate, such as paper. Full color inkjet printers use a plurality of ink reservoirs to store a number of differently colored inks for printing. A commonly known full color printer has four ink reservoirs. Each reservoir stores a different color ink, namely, cyan, magenta, yellow, and black ink, for the generation of full color images.
Phase change inkjet printers utilize ink that remains in a solid phase at room temperature. After the ink is loaded into a printer, the solid ink is transported to a melting device, which melts the solid ink to produce liquid ink. The liquid ink is stored in a reservoir that may be either internal or external to a printhead. The liquid ink is provided to the inkjet ejectors of the printhead as needed. If electrical power is removed from the printer to conserve energy or for printer maintenance, the melted ink begins to cool and may eventually return to the solid form. In this event, the solid ink needs to be melted again before the ink can be ejected by a printhead. Consequently, the time taken to melt the ink impacts the availability of a solid ink printer for printing operations. Therefore, improvements to the devices in a printer that heat and store melted ink are desirable.
A container for melting solid ink in a solid inkjet printer has been developed. The container comprises a housing comprised of thermally insulating material. The housing has a volume of space internal to the housing with a height, a width, and a depth. The container includes an inductive heater element positioned within the volume of space of the housing to melt ink within the volume of space. The heater element is configured to have a surface area that is greater than an area defined by the height and width of the volume of space.
In another embodiment, a printer comprises an ink loader configured to receive solid ink, and a melting device positioned to receive solid ink from the ink loader. The melting device is configured to heat the solid ink to a temperature for melting the solid ink and producing liquid. A container is fluidly connected to the melting device to receive melted solid ink from the melting device. The container includes a housing comprised of thermally insulating material. The housing has a volume of space internal to the housing having a height, a width, and a depth. An inductive heater element is positioned within the volume of space of the housing to melt ink within the volume of space. The heater element has a surface area that is greater than an area defined by the height and width of the volume of space.
The description below and the accompanying figures provide a general understanding of the environment for the system and method disclosed herein as well as the details for the system and method. In the drawings, like reference numerals are used throughout to designate like elements. The word “printer” as used herein encompasses any apparatus that generates an image on media with ink. The word “printer” includes, but is not limited to, a digital copier, a bookmaking machine, a facsimile machine, a multi-function machine, or the like. While the specification focuses on a system that controls the melting of solid ink in a solid ink reservoir, the apparatus for melting ink in a reservoir may be used with any device that uses a phase-change fluid that has a solid phase. Furthermore, solid ink may be called or referenced as ink, ink sticks, or sticks. The term “parametric volume” refers to a volume defined by an envelope around the form of an object, such as a heater element, that may include gaps and cavities. Thus, the parametric volume of an object includes open spaces within the object as well as the volume of material forming the object. Parametric volume as used in this document means an interior volume of a tight fitting, multi-sided box into which the heater fits.
In more detail, the ink handling system 12, which is also referred to as an ink loader, is configured to receive phase change ink in solid form, such as blocks of ink 14, which are commonly called ink sticks. The ink loader 12 includes feed channels 18 into which ink sticks 14 are inserted. Although a single feed channel 18 is visible in
The melted ink from the melting assembly 20 is directed gravitationally or by other means to a container for storage. The container includes a housing having a volume of space internal to the housing in which the ink is stored. The container is sometimes called a melted ink reservoir, an ink reservoir, or a melt reservoir. A separate reservoir 24 may be provided for each ink color, shade, or composition used in the printer 10. Alternatively, a single reservoir housing may be compartmentalized to contain the differently colored inks. As depicted in
The printing system 26 includes at least one printhead 28 having inkjets arranged to eject drops of melted ink. One printhead is shown in
The intermediate surface 30 includes a layer or film of release agent applied to rotating member 34 by the release agent application assembly 38, which is also known as a drum maintenance unit (DMU). The rotating member 34 is shown as a drum in
The media supply and handling system 48 of printer 10 is configured to transport print media along a media path 50 defined in the printer 10 that guides media through the nip 44, where the ink is transferred from the intermediate surface 30 to the print media 52. The media supply and handling system 48 includes at least one media source 58, such as supply tray 58 for storing and supplying print media of different types and sizes for the device 10. The media supply and handling system includes suitable mechanisms, such as rollers 60, which may be driven or idle rollers, as well as baffles, deflectors, and the like, for transporting media along the media path 50.
The media path 50 may include one or more media conditioning devices for controlling and regulating the temperature of the print media so that the media arrives at the nip 44 at a suitable temperature to receive the ink from the intermediate surface 30. For example, in the embodiment of
A control system 68 aids in operation and control of the various subsystems, components, and functions of the printer 10. The control system 68 is operatively connected to one or more image sources 72, such as a scanner system or a work station connection, to receive and manage image data from the sources and to generate control signals that are delivered to the components and subsystems of the printer. Some of the control signals are based on the image data, such as the firing signals, and these firing signals operate the printheads as noted above. Other control signals cause the components and subsystems of the printer to perform various procedures and operations for preparing the intermediate surface 30, delivering media to the transfix nip, and transferring ink images onto the media output by the imaging device 10.
The control system 68 includes a controller 70, electronic storage or memory 74, and a user interface (UI) 78. The controller 70 comprises a processing device, such as a central processing unit (CPU), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) device, or a microcontroller. Among other tasks, the processing device processes images provided by the image sources 72. The one or more processing devices comprising the controller 70 are configured with programmed instructions that are stored in the memory 74. The controller 70 executes these instructions to operate the components and subsystems of the printer. Any suitable type of memory or electronic storage may be used. For example, the memory 74 may be a non-volatile memory, such as read only memory (ROM), or a programmable non-volatile memory, such as EEPROM or flash memory.
User interface (UI) 78 comprises a suitable input/output device located on the imaging device 10 that enables operator interaction with the control system 68. For example, UI 78 may include a keypad and display (not shown). The controller 70 is operatively coupled to the user interface 78 to receive signals indicative of selections and other information input to the user interface 78 by a user or operator of the device. Controller 70 is operatively coupled to the user interface 78 to display information to a user or operator including selectable options, machine status, consumable status, and the like. The controller 70 may also be coupled to a communication link 84, such as a computer network, for receiving image data and user interaction data from remote locations.
The controller 70 generates control signals that are output to various systems and components of the printer 10, such as the ink handling system 12, printing system 26, media handing system 48, release agent application assembly 38, media path 50, and other devices and mechanisms of the printer 10 that are operatively connected to the controller 70. Controller 70 generates the control signals in accordance with programmed instructions and data stored in memory 74. The control signals, for example, control the operating speeds, power levels, timing, actuation, and other parameters, of the system components to cause the printer 10 to operate in various states, modes, or levels of operation, that are denoted in this document collectively as operating modes. These operating modes include, for example, a startup or warm up mode, various print modes, operational ready modes, maintenance modes, and power saving modes, such as standby or sleep.
When the printer is operating in a print mode or operational ready mode, the ink in the reservoirs is maintained in a liquid state by a heater associated with the reservoir. The heater is configured to output heat capable of maintaining the ink temperature within a predetermined range above the melting temperature for the ink. During some operating modes and device states, such as when the printer is shutdown, in a standby mode, or a power saving mode, the temperature of the ink is allowed to fall below the melting temperature by reducing the heat output by the heater or deactivating the heating system altogether. As a result, the ink is allowed to freeze, or solidify, to varying degrees within the reservoirs. When the printer 10 is returned to a print mode or an operational ready mode, the reservoir heater is activated to generate heat at a level capable of melting the solidified ink in the reservoirs and bring the temperature of the ink to a suitable temperature for printing.
One concern faced in transitioning a phase change ink printing device from a shutdown state, standby mode, or power saving mode to a print mode or ready mode is the amount of time required for the ink in the reservoirs to melt sufficiently to begin printing. Reservoir heaters have typically utilized heating elements located external to the ink in the reservoir. These heaters transfer thermal energy into the reservoir housing until the housing reaches a temperature that first melts the ink that is exposed to or in thermal contact with the reservoir housing. The thermal energy then migrates inwardly through the ink within the internal volume of the housing. Thus, the time required to bring a given volume of ink to a fully molten state depends at least in part on the amount of surface area of the ink available for exposure to thermal energy and the distance that the thermal energy must be conducted to fully permeate the mass. The surface area available for exposure to or contact with a heat source external to the ink, however, is limited by the geometry of the reservoir. To reduce the time required to bring ink to a fully molten state for printing, the ink may be heated at temperatures higher than would otherwise be required. The higher thermal output, however, increases the energy expenditure of the printer.
As an alternative to previously known reservoir heaters, the reservoirs of a phase change ink printer may be equipped with an inductive heating system. As discussed below, the inductive heating system includes a heating element configured to be immersed in the ink in a reservoir and to be inductively heated from a source external to the reservoir. Thus, thermal energy is generated within the volume of ink in the reservoir to avoid the need to heat the housing. In addition, the inductive heating element has a configuration or shape that enables a very high surface area to volume ratio in order to increase the heater surface area available for thermal contact with the ink. As a result, melting or elevating the temperature of a substantial portion of the volume of ink in a reservoir occurs much more rapidly than can occur with a heater that heats all or a portion of the ink reservoir. In addition, the heating element may be arranged proximate the outlet of the reservoir in order to melt ink in and around the outlet so that an initial melt volume is readily usable prior to establishing a fully molten state of the ink volume within the reservoir.
Referring now to
The housing 108 includes at least one inlet opening 112 and at least one outlet opening or conduit 114. Melted ink is introduced into the volume 110 through the inlet 112 from a source of melted ink, such as the melting assembly 20, a conduit, or from another reservoir. The inlet 112 is located in an upper portion of the housing 108 near or in the top surface or wall 116. In the embodiment of
Referring to
As depicted in
The inductive heating system 104 comprises an induction power supply 124, an induction coil 128, and an inductive heater element 130. The induction coil 128 is positioned exterior to the housing 108. The reservoir housing may be any material compatible with inductive heating of the heater element. The use of a plastic material for the housing 108 enables the incorporation of retaining and/or locating features 109 on the exterior of the housing to facilitate placement of the coil relative to the reservoir volume 110 and the heating element 130, which may also be positioned or affixed to the interior of the housing by use of incorporated location features. Electric leads 138 couple the induction coil 128 to the power supply 124. In operation, power supply 124 generates an alternating current that passes through the coil 128. The alternating current causes the coil 128 to produce an alternating magnetic field that impinges on the inductive heater element 130 in the reservoir chamber 110. As is known in the art, the alternating magnetic field induces heat in the inductive heater element 130 through eddy current losses and/or hysteresis. The controller 120 is coupled to the induction power supply 124 in order to activate the power supply 124 to generate the alternating current at one or more predetermined power levels and/or frequencies calculated to control the amount of heat generated in the heater element 130. By controlling the power level and frequency of the power supply 124 as well as other parameters, such as the coil 128 dimensions and positioning with respect to the heater element 130, a targeted level of heat may be rapidly generated in the heater element 130.
The heating element 130 is formed at least partially of a thermally conductive material capable of generating and maintaining heat levels suitable for melting ink in the reservoir in response to the magnetic fields from the coil 128. In one embodiment, the heating element is formed at least partially of a metal material, such as stainless steel, although any suitable thermally conductive material may be used. The heating element may have ferromagnetic properties that facilitate hysteresis heating of the heating element 130 in response to the alternating magnetic field.
The heating element is arranged in the reservoir volume 110 proximate the bottom 117 of the reservoir volume 110 and extending toward the top 116. In one embodiment, the parametric volume of the heater element 130 is greater than 50% of the total volume of the reservoir volume 110 up to the upper volume limit 134. As depicted in
The heating element 130 has a configuration or shape with a very high surface area in relation to the parametric volume of the heating element 130. In one embodiment, the heater element 130 has a shape that provides a surface area available for exposure to ink 102 that is greater than a surface area defined by the height H and width W of reservoir volume 110. A number of different shapes and configurations may be used for the heating element 130. For example, the heating element 130 may comprise a web, bundle, mesh, screen, braid, weave, or cluster of conductive fibers, strands, or filaments. Such a grouping of thin conductive material offers a readily attainable, very high surface area to volume ratio while providing sufficient space between the fibers and/or filaments to allow ink to flow through the outlet 114. The heating element 130 of
The controller 120 of the heating system 104 is operable to control the power level and/or frequency of the power supply 124 to enable the ink to be heated to temperatures appropriate for the mode of operation of the printer 10. For example, when the printer 10 is operated in a print mode or ready mode and the melting assembly 20 is activated to melt solid phase change ink to a melting temperature, melted ink flows into the reservoir volume 110 via the inlet 112. The controller 120 activates the power supply 124 at a level configured to maintain the ink received in the reservoir volume 110 in a liquid state. The melted ink may flow through the outlet 114 to the inkjet ejectors in the printhead 28. When transitioning from a print mode or ready mode to a standby mode or a power saving mode, the controller 120 may deactivate the power supply 124 or reduce the power level and/or frequency of the power supply 124 depending on the mode. As a result, the ink temperature may drop to or below the freezing point for the ink and the ink may solidify within the reservoir volume 110.
When the device transitions from a standby mode or power saving mode to a print mode or ready mode, the controller 120 activates the power source 124 to inductively heat the heating element 130. As heat is generated in the heating element 130, the solid ink 102 in areas proximate to the heater element 130 begin to melt first. The location of heater element 130 at a position proximate to outlet 114 enables ink melting to occur proximate the outlet 114 and melted ink to flow through the outlet 114 quickly after the heater 130 begins to heat. Thus, melted ink may flow through outlet 114 to printhead 28 even if other portions of the ink 102 in the reservoir volume 110 have not reached a fully molten state.
Referring now to
In another mode of operation, ink 102 occupies reservoir volume 110 in a solid phase. Controller 120 may open switch 144 to allow the ink 102 to cool and solidify according to various energy saving programs and techniques that are known to the art. Ink 102 may also solidify when a printing device is disconnected from electrical power for a time period sufficient to allow the ink to cool to the freezing point. When melting solidified ink, controller 120 closes switch 144 to enable electrical current from power source 124 to flow through leads 138 to the coil 128, causing the coil 128 to generate an alternating magnetic field that induces heat in the heater element 130. Heater element 130 applies heat uniformly across width W of reservoir volume 110. Due to the proximity of heater element 130 to inkjet ejectors 27 in the printhead 28, ink 102 near the ejectors 27 melts more quickly than ink in portions of the reservoir volume 110 that are farther from the inkjet ejectors 27. Thus, the ejectors 27 receive melted ink in a uniform manner across the width of the printhead and melted ink is available for ejection through the plurality of ejectors even if a portion of the ink 102 remains solid.
The embodiments described above are merely illustrative and are not limiting of alternative embodiments. Various implementations of an inductive heater element are described. In all cases, various non-heater components are compatible with the different implementations. For example, housing material, venting, temperature feedback control, reservoir volume, and fluid level volume limits may be used with any of the inductive heater elements. Inductive heater elements may be orientated in any way relative to the reservoir. Configurations incorporating angled folds, bends, holes, voids and the like enlarge the surface area of the heater element and enable gravity to urge liquefied ink to reservoir outlets. While
It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
