The present application is based on Japanese Patent Application No. 2005-013166 filed Jan. 20, 2005, the contents of which are incorporated herein by reference.
1. Field of the Invention
The present invention relates to an ink-jet printing head applicable to an image-recording apparatus arranged to perform a recording operation on a recording medium, with an ink delivered from nozzles.
2. Discussion of Related Art
There is known an ink-jet printing head of a type including a cavity unit and a piezoelectric actuator formed on the cavity unit. The cavity unit has a common manifold chamber from which an ink supplied from an ink supply source is distributed to a plurality of pressure chambers through which the ink is delivered to respective nozzles. When the ink in the selected pressure chambers is pressurized by the piezoelectric actuator, the pressurized ink in each selected pressure chamber is fed to the corresponding nozzle, and is ejected from this nozzle.
In the ink-jet printing head constructed as described above, each pressure chamber is in communication with both of the corresponding nozzle and the common manifold chamber, so that a pressure wave of the ink generated upon pressurization of the ink in the pressure chamber by the piezoelectric actuator has not only a forward component propagating toward the nozzle, but also a rearward component propagating toward the common manifold chamber. The rearward component of the pressure wave generates a so-called “cross talk” in which the rearward component propagates to the other nozzles through the common manifold chamber. This cross talk causes degradation of printing quality of the ink-jet printing head. To prevent the cross talk, it is known to provide the common manifold chamber with a damper which absorbs the rearward component of the pressure wave.
For example, JP-2003-11356 A (FIGS. 2-5) and US 2004001124 A1 (FIGS. 2 and 3) corresponding to JP-2004-25636 A disclose a cavity unit consisting of a plurality of plates laminated o each other, which include a nozzle plate having nozzles, a damper plate having a damper chamber, and a manifold plate having a common manifold chamber. The manifold plate and the damper plate are laminated on each other such that the common manifold chamber and the damper chamber are located adjacent to each other in the direction of lamination of those plates. In this arrangement, the cavity unit has a smaller surface area in cross section taken in a plane perpendicular to the direction of lamination, than in an arrangement in which the common manifold chamber and the damper chamber are formed in a single plate such that these two chambers are located adjacent to each other in the direction perpendicular to the direction of lamination of the cavity unit. Accordingly, the ink-jet printing head has a reduced overall size.
Described in greater detail, the cavity unit disclosed in JP-2003-11356 A uses the manifold plate formed of a metallic material such that the common manifold chamber takes the form of a recess which is formed in the manifold plate and which is partly defined by a thin bottom wall. The manifold plate is laminated on the damper plate such that the thin bottom wall of the recess serves as a top wall of the damper chamber. On the other hand, the cavity unit disclosed in US 2004001124 A1 uses the damper plate formed of a metallic material such that the damper chamber takes the form of a recess which is formed in the damper plate and which is partly defined by a thin top wall. The manifold plate is laminated on the damper plate such that the thin top wall of the damper chamber serves as a bottom wall of the common manifold chamber. In both of these cavity units, one of the opposite surfaces of the above-described thin wall partly defines the common manifold chamber while the other surface of the thin wall is exposed to an air space. In this arrangement, the rearward component of the pressure wave propagating from the pressure chamber to the common manifold chamber through a communication hole is absorbed by oscillation of the above-described thin wall of the metallic material.
In the cavity units disclosed in the above-identified two publications wherein the pressure wave propagating to the common manifold chamber is absorbed by the metallic thin wall, it is necessary to form the thin wall with a minimum thickness and/or a relatively large surface area, for effectively absorbing the pressure wave by a sufficiently large magnitude of oscillation of the thin wall.
However, there is a limitation in the reduction of the thickness of the thin wall with high accuracy by increasing the thickness of the above-described recess formed in the metallic manifold plate or damper plate. Further, an increase of the surface area of the thin wall gives rise to a problem of an increased size of the ink-jet printing head.
The present invention wad made in an effort to solve the problems experienced in the prior art. It is therefore an object of the present invention to provide an ink-jet printing head which is easy and economical to manufacture and small-sized and which permits effective absorption of the pressure wave of the ink propagating from the pressure chambers to the common manifold chamber.
The object indicated above can be achieved according to one aspect of the present invention, which provides an ink-jet printing head having a cavity unit, the cavity unit comprising a plurality of nozzles for ejecting an ink, a plurality of pressure chambers communicating with the respective nozzles, a common manifold chamber for distributing the ink into the plurality of pressure chambers, and a flexible plate having the plurality of nozzles and including a wall portion which partly defines the common manifold chamber and which constitutes a damper portion, wherein the damper portion absorbs a pressure wave of the ink propagating from each selected one of the pressure chambers to the common manifold chamber when the ink in each selected pressure chamber is pressurized to eject the ink from the corresponding nozzle.
In the ink-jet printing head according to the first aspect of this invention constructed as described, the damper portion absorbs the pressure wave propagating from the pressure chambers to the common manifold chamber, thereby preventing a cross talk between the nozzles which would take place due to the pressure wave propagating through the common manifold.
The damper portion is constituted by the flexible plate having the nozzles formed therethrough, more precisely, by the wall portion of the flexible plate which partly define the common manifold chamber. That is, the damper portion is provided by utilizing the flexible plate which is provided in the cavity unit of the ink-jet printing head, as a plate in which the nozzles are formed. Accordingly, the cavity unit can be fabricated with a reduced number of component plates and with a reduced overall thickness.
The object indicated above can also be achieved according to another aspect of this invention, which provides an ink-jet printing head having a cavity unit, the cavity unit comprising a plurality of nozzles for ejecting an ink, a plurality of pressure chambers communicating with the respective nozzles, a common manifold chamber for distributing the ink into the plurality of pressure chambers, a first plate formed of a flexible resin material and provided with a gas-impermeable film, and a damper portion which is constituted by a wall portion of the first plate which partly defines the common manifold chamber, the damper portion absorbing a pressure wave of the ink propagating from each selected one of the pressure chambers to the common manifold chamber when the ink in each selected pressure chamber is pressurized to eject the ink from the corresponding nozzle.
In the ink-jet printing head according to the second aspect of this invention constructed as described, the damper portion absorbs the pressure wave propagating from the pressure chambers to the common manifold chamber, thereby preventing a cross talk between the nozzles which would take place due to the pressure wave propagating through the common manifold.
The first plate is provided with the gas-impermeable film, to prevent entry of air into the common manifold chamber through the damper portions, and consequent generation of air bubbles in the common manifold chamber, even where the damper portion is formed of a gas-permeable resin material. Accordingly, the gas-impermeable film prevents a failure of ejection of the ink from the nozzles due to the air bubbles.
The above and other objects, features, advantages and technical and industrial significance of the present invention will be better understood by reading the following detailed description of a preferred embodiment of the invention, when considered in connection with the accompanying drawings, in which:
Referring to
As also shown in
In the present embodiment, each of the plates 11-15 has a thickness of about 50-150 μm, and the nozzle plate 11 is a flexible plate formed of a synthetic resin, while the other plates 12-15 are 42%-nickel alloy steel plates. The nozzle plate 11 has a multiplicity of ink ejecting nozzles 4 which are formed by laser machining, for example, and which have an extremely small diameter (about 20-23 μm). The nozzles 4 are arranged in five parallel straight rows such that the nozzles 4 in each row are spaced apart from each other by an extremely small spacing distance in the longitudinal direction of the nozzle plate 11 (in the X-axis direction), such that the corresponding nozzles 4 in the adjacent two rows are positioned relative to each other in a zigzag or staggered fashion, that is, offset from each other in the X-axis direction.
The cavity plate 15 has a multiplicity of through-holes forming a multiplicity of pressure chambers 36 arranged in five parallel straight rows such that the pressure chambers 36 in the adjacent two rows are positioned relative to each other in a zigzag fashion, that is, offset from each other in the X-axis direction. As shown in
The longitudinal end portion 36a of each pressure chamber 36 is held in communication with the corresponding nozzle 4 through a corresponding one of connecting passages 37 which are formed through the base plate 14, supply plate 13 and two manifold plates 12a, 12b such that the connecting passages 37 are arranged in five parallel straight rows in a zigzag fashion, like the nozzles 4.
The base plate 14 in contact with the lower surface of the cavity plate 15 has through-holes 38 in communication with the other longitudinal end portions of the respective pressure chambers 36.
The supply plate 13 in contact with the lower surface of the base plate 14 has communication holes 40 for supplying the ink from the common manifold chambers 7 to the pressure chambers 36. Each communication hole 40 has an inlet end portion 40a in communication with the corresponding common manifold chamber 7, an outlet end portion 40b in communication with the above-described through-hole 38 communicating with the corresponding pressure chamber 36, and an intermediate flow-restricting portion 40c located between the inlet and outlet end portions 40a, 40b. The flow-restricting portion 40c has a smaller cross sectional surface area than the inlet and outlet end portions 40a, 40b, so that a resistance to a flow of the ink through the flow-restricting portion 40c is larger than a resistance to flows of the ink through the inlet and outlet end portions 40a, 40b.
The two manifold plates 12a, 12b have the five elongate common manifold chambers 7 formed through their thicknesses, so as to extend in their longitudinal direction (in the X-axis direction) in parallel to the five rows of nozzles 4. As shown in
As described above, the lower surface of the lower manifold plate 12a is held in contact with the nozzle plate 11, so that the flexible nozzle plate 11 formed of the synthetic resin serves as the bottom wall of each common manifold chamber 7. That is, the portions of the nozzle plate 11 which serve as the bottom walls of the common manifold chambers 7 serve as damper portions 8, as shown in
In the present embodiment, the metal film 16 is formed on a substantially entire area of the lower surface of the nozzle plate 11 (over the entire lower surface area of the nozzle plate 11 except the portions in which the nozzles 4 are open). However, the metal film 16 need not cover the substantially entire area of the lower surface of the nozzle plate 11, and may be formed on only those portions of the lower surface which correspond to the damper portions 8. Namely, the metal film 16 must be formed on at least the above-indicated portions of the lower surface of the nozzle plate 11, to prevent the air permeation into the common manifold chambers 7 through the nozzle plate 11. Alternatively, the metal film 16 may be formed on the upper surface of the nozzle plate 11 on the side of the upper manifold plate 12a. The metal film 16 is formed on the nozzle plate 11 of polyimide resin by electroforming (electroplating) or vapor deposition process, with a thickness as small as about several microns (μm), and does not deteriorate the flexibility of the damper portions 8. Where the nozzle plate 11 is formed of a flexible material having gas impermeability, it is not necessary to form the metal film 16 or other gas-impermeable film on the nozzle plate 11.
To permit easier deformation of the damper portions 8 of the nozzle plate 11 as compared with the other portion, the nozzle plate 11 is provided with generally elongate weak portions 17 extending generally along the longitudinally extending opposite edges of the common manifold chambers 7. In the present embodiment, the weak portions 17 take the form of straight grooves formed in the upper surface of the nozzle plate 11 on the side of the lower manifold plate 12a, such that the grooves extending along the longitudinally extending opposite edges of the common manifold chambers 7 are located slightly outwards of those opposite edges, as shown in
As shown in
In the present embodiment wherein the four ink supply ports 47 are provided while the five common manifold chambers 7 are provided, as shown in
As shown in
Before the piezoelectric actuator 2 of plate type is bonded to the cavity unit 1, a sheet (not shown) of a suitable adhesive agent in the form of an ink-impermeable synthetic resin is bonded to the lower surface (lower one of the opposite major surfaces) of the piezoelectric actuator 2 which is to face the pressure chambers 36. Through this sheet of the adhesive agent, the piezoelectric actuator 2 is bonded to the cavity unit 1 such that the individual electrodes 44 are aligned with the respective pressure chambers 36. Further, the flexible flat cable 3 described above is bonded under pressure to the upper surface of the piezoelectric actuator 2, as shown in
In the ink-jet printing head 100 constructed as described above, the inks are delivered from the ink supply ports 47 to the nozzles 4 through ink flow passages. That is, the ink of each color is introduced from the corresponding ink supply port or ports 47 into the corresponding common manifold chamber or chambers 7, and is distributed to the individual pressure chambers 36 through the communication holes 40 formed through the supply plate 13, and through the through-holes 38 formed through the base plate 14. When the active portions of the piezoelectric actuator 2 are selectively polarized and displaced, the ink in the pressure chambers 36 corresponding to the displaced active portions is pressurized, and a pressure wave (more precisely, its forward component) of the pressurized ink propagates from the pressure chambers 36 to the corresponding nozzles 4 through the corresponding connecting passages 37, whereby the ink is ejected from the nozzles 4. At this time, the pressure wave (more precisely, its rearward component) propagates from the pressure chambers 36 also to the common manifold chambers 7 through the through-holes 38 and the communication holes 40. However, the bottom wall of each common manifold chambers 7 which is opposed to the inlet end portion 40a of the corresponding communication hole 40 functions as the damper portion 8, which is oscillated to effectively absorb the pressure wave, thereby preventing the cross talk which would take place due to the pressure wave propagating to the common manifold chamber 7.
The nozzle plate 11 is formed of a resin material, for facilitating the formation of the nozzles 4 therethrough, and is the lowermost plate of the cavity unit 1. In view of these facts, the damper portions 8 are not provided by adding a damper plate formed of a resin material, but are provided by utilizing this nozzle plate. In particular, the polyimide resin used for the nozzle plate 1 in the present embodiment has relatively high degrees of resistance to the ink and formability of the nozzles 4 by laser machining, for example, and a considerably high degree of flexibility which assures a sufficiently large magnitude of oscillation of the damper portions 8. Further, the lowermost nozzle plate 11 is exposed at its lower surface to the atmosphere, it is not necessary to form an air space within the cavity unit 1 such that the damper portions 8 are exposed to the air, to facilitate the deformation or flexing of the damper portions 8, as in the known ink-jet printing heads. Accordingly, the present cavity unit 1 can be formed at a reduced cost, with a reduced number of component plates, and with a reduced overall thickness in the direction of lamination of the plates.
It is also appreciated that the damper portions 8 formed of a synthetic resin having a lower degree of rigidity than metals are able to oscillate by an amplitude sufficient to effectively absorb the pressure wave of the ink, even where the damper portions 8 have a smaller surface area than the damper portions of the known cavity units. The damper portions 8 provided by the nozzle plate 1 may have a smaller thickness than the other portion of the nozzle plate 1, as shown in
The oscillation of the damper portions 8 is further facilitated by the weak portions 17, which are formed in the nozzle plate 11 to permit easier deformation of the damper portions 8. However, the weak portions 17 need not be provided.
The damper portions 8 are provided with the gas-impermeable film in the form of the metal film 16, to prevent entry of air into the common manifold chambers 7 through the damper portions 8, and consequent generation of air bubbles in the common manifold chambers 7, even where the damper portions 8 are formed of a gas-permeable resin material. Accordingly, the gas-impermeable film prevents a failure of ejection of the ink from the nozzles 4 due to the air bubbles. The gas-impermeable film may be formed on only those portions of the lower surface of the nozzle plate 11 which correspond to the respective damper portions 8, except the areas in which the nozzles 4 are formed.
Although the damper portions 8 are provided by the nozzle plate 11 in the illustrated embodiment, the damper portions 8 may be provided by adding a flexible plate in addition to the nozzle plate 11. In this case, the flexible plate which provides the damper portions 8 serves as the first plate.
While the piezoelectric actuator 2 is used in the illustrated embodiment as an actuator for pressurizing the ink in the selected pressure chambers 36, the actuator is not limited to the piezoelectric type.
It will be understood that the present invention is not limited to the details of the illustrated embodiment, but may be embodied with various changes and modifications, which may occur to those skilled in the art, without departing from the spirit and scope of the present invention defined in the following claims.
Number | Date | Country | Kind |
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2005-013166 | Jan 2005 | JP | national |
Number | Name | Date | Kind |
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4947184 | Moynihan | Aug 1990 | A |
5402159 | Takahashi et al. | Mar 1995 | A |
6045215 | Coulman | Apr 2000 | A |
6193360 | Nishiwaki et al. | Feb 2001 | B1 |
6250753 | Nishiwaki et al. | Jun 2001 | B1 |
6447107 | Chino et al. | Sep 2002 | B1 |
6712454 | Okuda | Mar 2004 | B2 |
20040001124 | Ito | Jan 2004 | A1 |
Number | Date | Country |
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3402349 | Mar 1992 | JP |
4341853 | Nov 1992 | JP |
200311356 | Jan 2003 | JP |
200425636 | Jan 2004 | JP |
Number | Date | Country | |
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20060158487 A1 | Jul 2006 | US |