Systems and methods herein generally relate to inkjet printers and more particularly inkjet printhead caps having rotatable panels that allows periodic printhead jet flushing while printheads are capped with the panels.
Inkjet printers eject drops of liquid marking material (e.g., ink) from nozzles or “jets” of printheads in patterns to perform printing. These nozzles of the inkjet printheads routinely clog when such are unused for extended periods, for example when an inkjet printer does not print for an extended period, or when certain colors or nozzles go unused for an extended period.
This can result in nozzles that do not eject any ink, or that only eject a significantly reduced drop mass, which causes less than optimal pixel placement (“streaky” solid-fill images) and lower than target drop mass (lighter than target solid-densities). If the condition goes uncorrected, it can lead to intermittent firing and the jet can eventually cease firing, and such a situation can be unrecoverable resulting in irreversible printhead damage. Depending on the pre-condition of the head, the time scale for onset of such unrecoverable failure could range from a few hours to an overnight/weekend idle time.
Additionally, certain colors (e.g., magenta, etc.) are more susceptible to clogging relative to other colors, because certain color inks dry faster than other color inks, which causes the ink to dry in the nozzles of the printhead during extended inactivity. Such nozzle clogging issues can be mitigated, but not avoided, by purge and cleaning cycles.
In order to address such issues, exemplary apparatuses herein include, among other components, a printhead that includes nozzles that are adapted to eject liquid ink. Structures herein also include a printhead resting/storage structure that is positioned to contact the printhead when the printhead is not ejecting the liquid ink. The printhead resting structure has a cap in which the printhead is parked when not printing.
With structures herein, the cap includes one or more rotatable panels that are connected to (hinged at) the top of the cap. Also, one or more nozzle contact pads (e.g., a flexible layer, foam pad, etc.) are on or connected to the rotatable panels. The rotatable panels are positioned to rotate to move the nozzle contact pads to contact the nozzles when the printhead contacts the cap, where rotation of the rotatable panels is caused by the printhead contacting the rotatable panels. The rotatable panels/nozzle contact pads can therefore be considered as an integral component of the cap (or as separate components that are connected to the cap). Also, a dispenser is positioned to dispense an ink stabilizing material on the nozzle contact pads when the printhead is not contacting the cap, and a drain is located at the bottom of the cap (e.g., distal to the top of the cap, where the printhead contacts the cap).
In greater detail, the rotatable panels each include an internal section that is positioned within the cap and an external section that extends outside the cap. The external section is positioned such that rotation of the rotatable panels is caused by the printhead contacting the external sections of the rotatable panels. More specifically, the printhead includes a nozzle plate containing the nozzles, and the rotatable panels and the nozzle contact pads are parallel to the nozzle plate when the printhead contacts the cap. Structurally, hinges connect the rotatable panels to the cap. The rotatable panels are connected to the hinges at a non-centered location along the rotatable panels to cause the rotatable panels to rest in the cap when the printhead is not contacting the rotatable panels.
Various methods herein can be adapted to periodically flush the printhead at different intervals for different color printheads or printheads using different types of inks; periodically flush the printhead only after an idle time period (during which the nozzles do not eject the liquid ink) has expired, which can be different for different colors or types of inks; etc. Thus, at the appropriate time, the methods herein dispense the ink stabilizing material from the dispenser on to the nozzle contact pads at some time when the printhead is not contacting the cap (e.g., before the printhead is to be parked on the cap for an extended period).
Once the ink stabilizing material has been applied to the nozzle contact pads, methods herein contact the printhead with the cap (when nozzles of the printhead are not ejecting liquid ink). The rotatable panels are positioned to rotate to move the nozzle contact pads to contact the nozzles when the printhead contacts the cap, where contacting the printhead to the rotatable panels moves the nozzle contact pads to contact the nozzles. Again, the rotatable panels include an internal section that is positioned within the cap and an external section that extends outside the cap, and the process of contacting the printhead contacts the printhead to the external section to rotate the rotatable panels to move the nozzle contact pads to contact the nozzles. This rotates the rotatable panels to position the rotatable panels and the nozzle contact pads parallel to the nozzle plate when the printhead contacts the cap.
With the printhead on the cap and the nozzle contact pads contacting the nozzle plate and the nozzles, methods herein allow continuous periodic flushing of the printhead by periodically alternating between: ejecting a mixture of the ink stabilizing material and the ink from the nozzles; and drawing the mixture of the ink stabilizing material and the ink into the nozzles.
Specifically, with the ink stabilizing material on the rotatable panels and the nozzles contacting the rotatable panels, ink is ejected from the nozzles to cause the ink to mix with the ink stabilizing material and form continuous film mixture. After expiration of a first time period, this processing then draws the ink and stabilizing material mixture back into the nozzles and keeps the ink and stabilizing material mixture in the ends of the nozzles for a second time period. After the second time period has expired, the nozzles once again eject the ink/stabilizing material mixture with additional ink on the rotatable panels and the process repeats. The ink/stabilizing material mixture is raised and lowered in the nozzles in this way (with pause periods between raising and lowering) periodically to draw the ink stabilizing material into and out of the nozzles continuously over the printhead storage period.
Any excess ink/stabilizing material mixture that flows off the rotatable panels will drain into the cap. When the printhead is uncapped for printing, the rotatable panels drop into the cap and the ink/stabilizing material mixture is rinsed off the rotatable panels during the printhead purge and wipe, or the capping station can pass under a wash station that rinses the rotatable panels with more ink stabilizing material, which re-forms the ink stabilizing material film on the panels so that they are ready for the next printhead storage.
These and other features are described in, or are apparent from, the following detailed description.
Various exemplary systems and methods are described in detail below, with reference to the attached drawing figures, in which:
As mentioned above, nozzles of inkjet printheads routinely clog when such are unused for extended periods, and purge and cleaning cycles are not completely effective at preventing clogs. In view of such issues, apparatuses herein provide inkjet printhead caps having rotatable panels that allows continuous printhead jet flushing while printheads are capped by the panels.
More specifically, structures herein cap the printheads with self-actuating rotatable panels (such as plastic shutters) located inside the capping station. More specifically, the printheads are mounted on a print bar that raises and lowers the printheads for capping, cleaning, and docking with the marking transport during printing. The rotatable panels are hinged along the axis of the capping station with tabs that protrude outside the station. When the print bar contacts the tabs, the rotatable panels rotate to directly contact the printhead faceplate as the printhead seals against the capping station. One of the tabs is longer than the other so that one rotatable panel begins to lift before the other, where the rotatable panels eventually overlap and form a continuous seal against the printhead faceplate.
In processing herein, the rotatable panels are rinsed with any form of ink stabilizing material (e.g., cleaning fluid, water, solvent, etc.) appropriate to the ink used in the printhead prior to capping the printhead. A thin film of this ink stabilizing material remains on the rotatable panels and forms a fluidic seal between the rotatable panels and printhead faceplate when the printhead is capped.
After the printhead is capped, the printhead is purged or the nozzles are actuated to release a small amount of ink from the nozzles into the film of ink stabilizing material trapped between the rotatable panels and printhead faceplate to ensure a continuous film of fluid. The printhead meniscus vacuum is then increased to draw the mixture of ink stabilizing material and ink into the nozzles. After a period of time, the meniscus vacuum is lowered to purge the cleaning fluid and a small volume of ink from the nozzles back between the rotatable panels and faceplate. The meniscus vacuum is raised and lowered in this way periodically to draw the cleaning fluid into and out of the nozzles in a continuous periodic process over the printhead storage period.
Any excess ink that is purged from the printhead and mixes with the cleaning fluid can flow off the rotatable panels and into the cap. When the printhead is uncapped for printing, the rotatable panels drop into the capping station and the mixture of cleaning fluid and ink is rinsed off during the printhead purge and wipe, or the capping station can pass under a wash station that rinses the rotatable panels with cleaning fluid, which re-forms the ink stabilizing material film on the panels.
The inkjet print cartridges 104 remain connected to the cartridge resting structures 102 unless the inkjet printing engine 100 is in the process of using the inkjet print cartridges 104 for printing. When printing markings on the sheet of print media 106, the inkjet printers 100 eject drops (droplets) of liquid marking material (e.g., ink, etc.) from nozzles 118 (jets) of inkjet printheads 116 in patterns to perform the printing on the print media 106. After printing, the inkjet print cartridges 104 again return to the cartridge resting structures 102.
As shown in
Again, the nozzles 118 of such inkjet printheads routinely clog when such are unused for extended periods. In order to address such issues, apparatuses herein include one or more asymmetric rotatable panels 120, 122 that are connected to the top of the cap 112, as shown in cross-sectional view in
As additionally shown in
This is shown in greater detail in the expanded cross-sectional views presented in
The rotatable panels 120, 122 are formed of any material (such as plastics, polymers, metals, alloys, ceramics, fiber materials, etc.) that has sufficient stiffness/rigidity to retain the existing shape (avoid excessive deformation) when rotated into position to contact the cartridge resting structure 102 and/or wash station 150. The optional nozzle contact pads 124 are more flexible (have a greater elasticity measure) relative to the rotatable panels 120, 122. The more compliant, more flexible nozzle contact pads 124 increase the surface area contact with the printhead 116 and nozzles 118 and helps the mixture of ink stabilizing material 152 and ink form a fluidic seal at the ends of the nozzles 118 to prevent the ink in the nozzles 118 from drying.
Structurally, hinges 126 connect the rotatable panels 120, 122 to the top of the cap 112. Therefore, the rotatable panels 120, 122/nozzle contact pads 124 can therefore be considered as an integral component of the cap 112 (or as separate components that are connected to the cap 112).
In greater detail, the rotatable panels 120, 122 each include an external section (sometimes referred to as a tab) 120A, 122A that extends outside the cap 112 and an internal section 120B, 122B that is positioned within the cap 112. Additionally, one of the rotatable panels 120 can optionally include the third section 120C that has a reduced thickness relative to the other sections. Note that many of such identification numerals are omitted from
As can be seen in
As shown in
As shown in
This causes the end of one rotatable panel 120 to sit lower (e.g., by distance D) than the other rotatable panel 122, as shown in
This rotation continues as the inkjet printhead 116 moves into full contact with the cap 112, which results in the surfaces of the rotatable panels 120, 122 (and the surfaces of the optional nozzle contact pads 124) being parallel to the bottom of the inkjet printhead 116 (parallel to the bottom of the nozzle plate 118A), as shown in
The meniscus control 158 (
This allows the meniscus control 158 to be controlled to periodically flush the printhead 116, continuously during the printhead storage period. This continuous process periodically flushes the nozzles 118 by alternating between ejecting the ink 140 from the nozzles 118 and drawing the mixture of the ink stabilizing material 152 and the ink 140 back into the nozzles 118. Specifically, with the ink stabilizing material 152 on the rotatable panels 120, 122 and the nozzles 118 contacting the rotatable panels 120, 122, ink 140 is ejected from the nozzles 118 to cause the ink 140 to mix with the ink stabilizing material 152 and form continuous film mixture 140/152. After a first time period has expired, this processing then draws the ink 140 and stabilizing material 152 mixture back into the nozzles 118 and keeps the ink 140 and stabilizing material 152 mixture in the ends of the nozzles 118 for a second time period. After the second time period has expired, the nozzles 118 once again eject the ink 140/stabilizing material 152 mixture with additional ink 140 on the rotatable panels 120, 122 and the process continually repeats until the printhead 116 is needed for printing.
Thus, the ink 140/stabilizing material 152 mixture is raised and lowered in the nozzles 118 in this way periodically to draw the ink stabilizing material 152 into and out of the nozzles 118 continuously over the printhead 116 storage period. During such processing, additional ink 140 will be added to the ink/stabilizing material mixture 140/152 that is between the rotatable panels 120, 122 and the bottom of the nozzle plate 118A. Any excess ink 140/stabilizing material 152 mixture that flows off the rotatable panels 120, 122 will drain into the cap 112. Further, once a sufficient amount of ink 140 has been added to the ink/stabilizing material mixture 140/152, and the ink/stabilizing material mixture 140/152 will be diluted of ink stabilizing material mixture 152, and then the cartridge resting structure 102 can be returned to the wash station 150 (see
When the printhead 116 is uncapped from the cap 112 for printing (shown in
In addition, each different meniscus control 158 in each different print cartridge 104 is adapted to periodically flush the printhead 116 at different intervals for different type inks or colors, periodically flush the printhead only after an idle time period (during which the nozzles do not eject the liquid ink) has expired, which can be different for different inks or colors, etc.
While two rotatable panels are shown in the foregoing examples, a single rotatable panel could be used with structures herein. For example, as shown in
Once the ink stabilizing material has been applied to rotatable panels (potentially having the nozzle contact pads thereon) methods herein contact the printhead with the cap in item 172. The rotatable panels are positioned to rotate to move the nozzle contact pads to contact the nozzles when the printhead contacts the cap in item 172. If the nozzle contact pads are used, the process of contacting the printhead to the rotatable panels in item 172 moves the nozzle contact pads to contact the nozzles. Again, the rotatable panels include an internal section that is positioned within the cap and an external section that extends outside the cap, and the process of contacting the printhead contacts the printhead to the external section to rotate the rotatable panels to move the nozzle contact pads to contact the nozzles. This rotates the rotatable panels to position the rotatable panels and the nozzle contact pads parallel to the nozzle plate when the printhead contacts the cap.
With the printhead on the cap and the nozzle contact pads contacting the nozzle plate and the nozzles, methods herein flush the printhead in items 174-178 in a continuous process by periodically alternating between: ejecting a mixture of the ink stabilizing material and the ink from the nozzles 174; drawing the mixture of the ink stabilizing material and the ink back into the nozzles 176; and repeating such flush processing 178 until more ink stabilizing material is applied (182-170), or until printing is to resume (186).
Specifically, with the ink stabilizing material on the rotatable panels and the nozzles contacting the rotatable panels, ink is ejected from the nozzles to cause the ink to mix with the ink stabilizing material and form continuous film mixture of ink and ink stabilizing material in item 174. This processing then draws the ink and stabilizing material mixture back into the nozzles and keeps the ink and stabilizing material mixture in the ends of the nozzles for an established time period in item 176. After the time period has expired, the nozzles once again eject the ink/stabilizing material mixture with additional ink on the rotatable panels (processing in item 178 causes processing in item 174 to be repeated). The ink/stabilizing material mixture is raised (174) and lowered (176) in the nozzles in this way periodically to draw the ink stabilizing material into and out of the nozzles continuously over the printhead storage period. Any excess ink/stabilizing material mixture that flows off the rotatable panels will drain into the cap.
These methods can periodically flush the printhead (174-178) at different intervals for different color printheads, or for printheads that use different types of inks; periodically flush the printhead (174-178) only after an idle time period (during which the nozzles do not eject the liquid ink) has expired, which can be different for different colors or types of inks; etc.
The printhead is uncapped in item 180, which causes the rotatable panels drop into the cap, after which a purge process clears the ink/stabilizing material mixture from the nozzles. In the purging part of uncapping in item 180, a sufficient quantity of ink is ejected from the nozzles into the cap until all the ink/stabilizing material mixture had been cleared from the nozzles and the nozzles are only ejecting ink. After purging, the nozzles are wiped with the wiper, which is included in the processing shown in item 180. If the ink stabilizing film is to be reformed on the rotatable panels, item 182 returns processing to item 170 to re-apply the ink stabilizing material and re-form the ink stabilizing film. If the film is not to be reformed, the cap can be drained in item 184 and printing can be performed in item 186 (which may include purge/wipe processing, etc., before actual printing).
The input/output device 214 is used for communications to and from the printing device 204 and comprises a wired or wireless device (of any form, whether currently known or developed in the future). The tangible processor 224 controls the various actions of the printing device 204. A non-transitory, tangible, computer storage medium device 210 (which can be optical, magnetic, capacitor based, etc., and is different from a transitory signal) is readable by the tangible processor 224 and stores instructions that the tangible processor 224 executes to allow the computerized device to perform its various functions, such as those described herein. Thus, as shown in
The printing device 204 includes at least one marking device (printing engine(s)) 100 that use marking material, and are operatively connected to a specialized image processor 224 (that may be different from a general purpose computer because it is specialized for processing image data), a media path 236 positioned to supply continuous media or sheets of media from a sheet supply 230 to the marking device(s) 100, etc. After receiving various markings from the printing engine(s) 100, the sheets of media can optionally pass to a finisher 234 which can fold, staple, sort, etc., the various printed sheets. Also, the printing device 204 can include at least one accessory functional component (such as a scanner/document handler 232 (automatic document feeder (ADF)), etc.) that also operate on the power supplied from the external power source 220 (through the power supply 218).
The one or more printing engines 100 are intended to illustrate any marking device that applies marking material (toner, inks, plastics, organic material, etc.) to continuous media, sheets of media, fixed platforms, etc., in two- or three-dimensional printing processes, whether currently known or developed in the future. The printing engines 100 can include, for example, inkjet printheads, contact printheads, three-dimensional printers, etc.
Thus, the processor 224 can be adapted to control the meniscus control 158 to periodically flush the printhead 116 at different intervals for different color printheads or printheads using different types of inks; periodically flush the printhead 116 only after an idle time period (during which the nozzles do not eject the liquid ink) has expired, which can be different for different colors or types of inks; etc.
While some exemplary structures are illustrated in the attached drawings, those ordinarily skilled in the art would understand that the drawings are simplified schematic illustrations and that the claims presented below encompass many more features that are not illustrated (or potentially many less) but that are commonly utilized with such devices and systems. Therefore, Applicants do not intend for the claims presented below to be limited by the attached drawings, but instead the attached drawings are merely provided to illustrate a few ways in which the claimed features can be implemented.
The terms printer or printing device as used herein encompasses any apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, etc., which performs a print outputting function for any purpose. The details of printers, printing engines, etc., are well-known and are not described in detail herein to keep this disclosure focused on the salient features presented. The systems and methods herein can encompass systems and methods that print in color, monochrome, or handle color or monochrome image data.
In addition, terms such as “right”, “left”, “vertical”, “horizontal”, “top”, “bottom”, “upper”, “lower”, “under”, “below”, “underlying”, “over”, “overlying”, “parallel”, “perpendicular”, etc., used herein are understood to be relative locations as they are oriented and illustrated in the drawings (unless otherwise indicated). Terms such as “touching”, “on”, “in direct contact”, “abutting”, “directly adjacent to”, etc., mean that at least one element physically contacts another element (without other elements separating the described elements). Further, the terms automated or automatically mean that once a process is started (by a machine or a user), one or more machines perform the process without further input from any user. In the drawings herein, the same identification numeral identifies the same or similar item.
It will be appreciated that the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. 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. Unless specifically defined in a specific claim itself, steps or components of the systems and methods herein cannot be implied or imported from any above example as limitations to any particular order, number, position, size, shape, angle, color, or material.
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