Patent Grant
10272692
This application is based upon and claims the benefit of priority from Japanese Patent Application No. 2016-178773, filed Sep. 13, 2016, and Japanese Patent Application No. 2017-143838, filed Jul. 25, 2017, the entire contents of each are incorporated herein by reference.
Embodiments described herein relate generally to a liquid circulation device, a liquid ejection apparatus, and a liquid ejection method.
In an existing liquid ejection apparatus, a liquid ejection head ejects liquid and a liquid circulation device circulates the liquid through a circulation path. The liquid ejection apparatus adjusts a liquid pressure of a nozzle of the liquid ejection head by using a pump for adjusting the pressure in a plurality of tanks provided in the circulation path. However, if the capacity of the pump changes over time, it is difficult to adjust the liquid pressure.
In general, according to one embodiment, A liquid circulation device includes a circulation path through which a liquid circulates through a liquid ejection head, a first pump in the circulation path on a first side of the liquid ejection head, a second pump in the circulation path on a second side of the liquid ejection head, an adjustment tank in the circulation path between the first pump and the second pump, an upstream tank in the circulation path between the liquid ejection head and the first pump, a downstream tank in the circulation path between the liquid ejection head and the second pump, a first pressure sensor configured to detect a pressure in the upstream tank, a second pressure sensor configured to detect a pressure in the downstream tank, and a controller connected to the first and second pumps and configured to control the first and second pumps based on detected pressures in the upstream and downstream tanks.
Hereinafter, a liquid ejection apparatus 10 according to an example embodiment and an ink jet recording apparatus 1 including the liquid ejection apparatus 10 will be described with reference to
The ink jet recording apparatus 1 illustrated in
As illustrated in
The plurality of liquid ejection apparatuses 10 respectively eject inks of a plurality of colors, for example, a cyan ink, a magenta ink, a yellow ink, a black ink, and a white ink. The colors or characteristics of the inks I to be used are not limited. For example, instead of a white ink, a transparent glossy ink, a special ink which develops a color when the ink is irradiated with infrared rays or ultraviolet rays, or the like may be ejected. The plurality of liquid ejection apparatuses 10 have the same configuration and may use different inks.
The liquid ejection head 20 illustrated in
In the liquid ejection head 20, the nozzle plate 21, the board 22, and the manifold 23 form the predetermined-shaped ink flow path 28 including the ink pressure chambers 25 therein. The actuator 24 including electrodes 24a and 24b is provided on the portion of the board 22 that faces each of the ink pressure chambers 25. The actuator 24 is connected to a driving circuit. The actuator 24 is deformed according to a voltage controlled by a module control unit 38, and thus the liquid ejection head 20 ejects the liquid from the nozzle hole 21a which is disposed so as to face the actuator 24.
As illustrated in
The circulation device 30 includes a cartridge 51 as a supply tank provided outside of the circulation path 31, a supply path 52, and a supply pump 53. The cartridge 51 is configured so as to store the ink to be supplied to the intermediate tank 32, and an air chamber in the cartridge 51 is opened to the atmosphere. The supply path 52 is a flow path that connects the intermediate tank 32 and the cartridge 51. The supply pump 53 is provided on the supply path 52, and feeds the ink in the cartridge 51 to the intermediate tank 32.
A first flow path 31a, a second flow path 31b, a third flow path, 31c and a fourth flow path 31d that constitute the circulation path 31 and the supply path 52 each include a pipe peripherally covered with a metal or a resin material and tubes, for example, Polytetrafluoroethylene (PTFE) tubes. The circulation path 31 includes the first flow path 31a which connects the intermediate tank 32 and the upstream tank 34, the second flow path 31b which connects the upstream tank 34 and a supply port 20a of the liquid ejection head 20, the third flow path 31c which connects a collection port 20b of the liquid ejection head 20 and the downstream tank 35, and the fourth flow path 31d which connects the downstream tank 35 and the intermediate tank 32.
The circulation path 31 extends from the intermediate tank 32 to the supply port 20a of the liquid ejection head 20 via the first flow path 31a and the second flow path 31b, and from the collection port 20b of the liquid ejection head 20 to the intermediate tank 32 via the third flow path 31c and the fourth flow path 31d.
The intermediate tank 32 is connected to the liquid ejection head 20 via the circulation path 31, and is configured so as to store the liquid. A separating film 32a, for example, polyimide or PTFE, is formed on a liquid surface of the intermediate tank 32 to prevent air bubbles from entering the intermediate tank 32. The intermediate tank 32 includes an opening and closing valve 37 configured to open an air chamber in the intermediate tank 32 to the atmosphere. Further, a liquid level sensor 54 is provided on the liquid surface of the intermediate tank 32.
The upstream tank 34 is disposed upstream of the liquid ejection head 20, and is configured so as to store the liquid. A separating film 34a, for example, polyimide or PTFE, is formed on a liquid facing surface of the upstream tank 34 to prevent air bubbles from entering the upstream tank 34. The upstream tank 34 includes a first pressure sensor 39a as a first pressure detection unit.
The downstream tank 35 is disposed downstream of the liquid ejection head 20, and is configured so as to store the liquid. A separating film 35a, for example, polyimide or PTFE, is formed on a liquid facing surface of the downstream tank 35 to prevent air bubbles from entering the downstream tank 35. The downstream tank 35 includes a second pressure sensor 39b as a second pressure detection unit.
The first pressure sensor 39a detects a pressure of the air chamber in the upstream tank 34, and transmits the detected data to the module control unit 38.
The second pressure sensor 39b detects a pressure of the air chamber in the downstream tank 35, and transmits the detected data to the module control unit 38.
The first pressure sensor 39a and the second pressure sensor 39b output pressures as electric signals using, for example, semiconductor piezoresistive pressure sensors. The semiconductor piezoresistive pressure sensor includes a diaphragm which receives an external pressure, and a semiconductor strain gauge formed on the surface of the diaphragm. The semiconductor piezoresistive pressure sensor detects a pressure by converting a change in electric resistance into an electric signal, the change in electric resistance being caused by a piezoresistive effect which occurs in the strain gauge due to deformation of the diaphragm by the external pressure.
The liquid level sensor 54 includes a float 55 which floats on the liquid surface and moves up and down and hole ICs 56a and 56b provided at two predetermined upper and lower positions. The liquid level sensor 54 detects an amount of ink in the intermediate tank 32 by detecting that the float 55 reaches the upper limit position and the lower limit position with the hole ICs 56a and 56b, and transmits the detected data to the module control unit 38.
The opening and closing valves 37a and 37b are respectively provided at the intermediate tank 32 and the downstream tank 35. The opening and closing valves 37a and 37b may be, for example, normally-closed type solenoid opening and closing valves, which are opened when the power is turned on and are closed when the power is turned off. The opening and closing valves 37a and 37b are configured to open and close the air chambers of the intermediate tank 32 and the downstream tank 35 to and from the atmosphere as controlled by the module control unit 38.
The first circulation pump 33 is provided on the first flow path 31a of the circulation path 31. The first circulation pump 33 is disposed between a portion on a primary side (e.g., right hand side in figure) of the liquid ejection head 20 and the intermediate tank 32 and upstream of the upstream tank 34. The first circulation pump 33 feeds the liquid toward the liquid ejection head 20 disposed downstream of the upstream tank 34.
The second circulation pump 36 is provided on the fourth flow path 31d of the circulation path 31. The second circulation pump 36 is disposed between a portion on a secondary side (e.g., left hand side in the figure) of the liquid ejection head 20 and the intermediate tank 32 and downstream of the downstream tank 35. The second circulation pump 36 feeds the liquid toward the intermediate tank 32 disposed downstream of the downstream tank 35.
The supply pump 53 is provided on the supply path 52. The supply pump 53 feeds the ink I stored in the cartridge 51 toward the intermediate tank 32.
The first circulation pump 33, the second circulation pump 36, and the supply pump 53 each include, for example, a piezoelectric pump 60 as illustrated in
As illustrated in
The module control unit 38 is connected to and communicates with the host computer 13 connected to the host computer 13 via the communication interface 73, and receives various information such as operation conditions.
An input operation by a user or an instruction from the host computer 13 for the ink jet recording apparatus 1 is transmitted to the CPU 71 of the module control unit 38 via the communication interface 73. Various information acquired by the module control unit 38 is input to an application program or transmitted to the host computer 13 of the ink jet recording apparatus 1 via the communication interface 73.
The CPU 71 corresponds to a central processor of the module control unit 38. The CPU 71 controls each hardware unit according to an operating system and an application program to realize various functions of the liquid ejection apparatus.
The CPU 71 is connected to driving circuits 75a, 75b, and 75c which drive the various pumps 33, 36, and 53 of the circulation device 30 and the various sensors 39a, 39b, and 54.
For example, the CPU 71 can function as a circulation section controlling operations of the circulation pumps 33 and 36 to circulate the ink.
The CPU 71 can function as a supply section controlling an operation of the supply pump 53 based on the information detected by the liquid level sensor 54 and the pressure sensors 39a and 39b, to supply the ink from the cartridge 51 to the circulation path 31.
Further, the CPU 71 can function as a pressure adjustment section controlling the liquid feeding capacity of the first circulation pump 33 and the liquid feeding capacity of the second circulation pump 36 based on the information detected by the first pressure sensor 39a, the second pressure sensor 39b, and the liquid level sensor 54, to adjust an ink pressure in the nozzle hole 21a.
The storage unit 72 includes, for example, a program memory and a RAM. The storage unit 72 stores an application program and various setting values. The storage unit 72 stores various setting values such as a formula for calculating the ink pressure in the nozzle hole 21a, a target pressure range, and a maximum adjustment value of each pump, as control data to be used for pressure control.
Hereinafter, a liquid ejection method of the liquid ejection apparatus 10 and a control method of the liquid ejection apparatus 10 according to the second embodiment will be described with reference to the flowchart of
In Act 1, the CPU 71 waits for an instruction to start circulation. For example, when an instruction to start circulation is detected by a command from the host computer 13, the process proceeds to Act 2. As a printing operation, the host computer 13 controls the liquid ejection head 20 ejecting an ink toward the recording medium S while the liquid ejection apparatus 10 reciprocates in a direction perpendicular to a direction in which the medium support mechanism 12 moves the recording medium S. Specifically, the CPU 71 controls the head support mechanism 11 transporting a carriage 11a toward the recording medium S, and reciprocating the carriage 11a in the direction of the arrow A. The CPU 71 transmits an image signal according to the desired image to a driving circuit 75e of the liquid ejection head 20. The driving circuit 75e selectively drives the actuator 24 of the liquid ejection head 20, and ejects ink droplets from the nozzle hole 21a onto the recording medium S.
In Act 2, the CPU 71 controls the first circulation pump and the second circulation pump 36 starting an ink circulation operation. The ink I circulates from the intermediate tank 32, through the upstream tank 34, into the liquid ejection head 20, and flow back into the intermediate tank 32 via the downstream tank 35. By this circulation operation, impurities included in the ink I are removed by a filter provided in the circulation path 31.
In Act 3, the CPU 71 controls the opening and closing valve 37 opening such that the intermediate tank 32 is opened to the atmosphere. Since the intermediate tank 32 is opened to the atmosphere and thus maintains a constant pressure, a pressure drop in the circulation path due to ink consumption of the liquid ejection head 20 can be prevented. When there is a concern that a temperature of the intermediate tank 32 may increase due to the opening and closing valve 37 being open for an extended period of time, the opening and closing valve 37 may be periodically opened for a brief period of time. If the pressure in the circulation path does not excessively decrease, the ink pressure in the nozzle can be maintained constant while the opening and closing valve 37 is closed. The solenoid opening and closing valve 37 is a normally-closed type valve. Thus, even when supply of the power to the apparatus suddenly stops due to a power failure or the like, the opening and closing valve 37 is instantaneously closed. Consequently, the intermediate tank 32 can be blocked from an atmospheric pressure and the circulation path 31 can be sealed. Therefore, it is possible to prevent the ink I from dropping from the nozzle hole 21a of the liquid ejection head 20.
In Act 4, the CPU 71 detects upstream pressure data and downstream pressure data transmitted from the first pressure sensor 39a and the second pressure sensor 39b. The CPU 71 further detects a liquid level of the intermediate tank 32 based on data transmitted from the liquid level sensor 54.
In Act 5, the CPU 71 starts a liquid level adjustment. Specifically, the CPU 71 controls the supply pump 53 supplying the ink from the cartridge 51 based on the detection result of the liquid level sensor 54, thereby adjusting a liquid level position. For example, at the time of printing, ink droplets ID are ejected from the nozzle hole 21a, and the ink amount of the intermediate tank 32 instantaneously decreases. When the liquid level falls, the ink is supplied. When the ink amount again increases and output of the liquid level sensor 54 reverses, the CPU 71 controls the supply pump 53 stopping supply the ink to the intermediate tank 32.
In Act 6, the CPU 71 detects the ink pressure in the nozzle from the pressure data. Specifically, based on the upstream pressure data and the downstream pressure data transmitted from the pressure sensor, the ink pressure in the nozzle hole 21a is calculated using a predetermined formula.
For example, the ink pressure Pn of the nozzle can be obtained by adding a pressure ρgh which is generated due to a height difference between liquid levels of the upstream tank 34 and the downstream tank 35, and a surface of the nozzle, to an average value of a pressure value Ph of the air chamber of the upstream tank 34 and a pressure value Pl of the air chamber of the downstream tank 35. Here, ρ is a density of the ink, g is a gravity acceleration, and h is a height distance between the liquid levels of the upstream tank 34 and the downstream tank 35, and the surface of the nozzle. The separating film 34a and the separating film 35a are located at liquid levels of the upstream tank 34 and the downstream tank 35, respectively. The separating film 34a and the separating film 35a may be located at the same height.
As a pressure adjustment process, the CPU 71 calculates a driving voltage based on the ink pressure Pn of the nozzle that is calculated from the pressure data. The CPU 71 controls the first circulation pump 33 and the second circulation pump 36 such that the ink pressure Pn of the nozzle becomes an appropriate value. Thus, it is possible to prevent the ink I from leaking from the nozzle hole 21a of the liquid ejection head 20, while maintaining a negative pressure at the nozzle hole. However, the negative pressure is maintained low enough not to draw air bubbles from the nozzle hole into the intermediate tank 32 such that the nozzle hole maintains a meniscus Me. Here, as an example, it is assumed that the upper limit of a target value is P1H and the lower limit of a target value is P1L.
In Act 7, the CPU 71 determines whether the ink pressure Pn of the nozzle is within an appropriate range, that is, whether P1L≤Pn≤P1H is satisfied. When the ink pressure Pn of the nozzle is not within the appropriate range (No in Act 7), in Act 8, the CPU 71 determines whether or not the ink pressure Pn of the nozzle exceeds the upper limit P1H of the target value.
The ink pressure in the nozzle of the liquid ejection head 20 is increased when the first circulation pump 33 is driven more strongly than the second circulation pump 36, and is decreased when the second circulation pump 36 is driven more strongly than the first circulation pump 33.
Further, the CPU 71 determines whether or not the driving voltages are within adjustment ranges (between a minimum driving voltage and a maximum driving voltage) of the first circulation pump 33 and the second circulation pump 36, respectively (Act 9 and Act 12). When either of the driving voltages of the first circulation pump 33 and the second circulation pump 36 exceed maximum adjustment values Vmax of the pumps 33 and 36, the CPU 71 increases or decreases the ink pressure in the nozzle by changing a driving voltage of the pump 36 or the pump 33, the driving voltage of which does not exceed the maximum adjustment value Vmax.
More specifically, when the ink pressure Pn of the nozzle is not within the appropriate range (No in Act 7), and the ink pressure Pn of the nozzle does not exceed the upper limit of the target value P1H (No in Act 8), that is, when the ink pressure Pn of the nozzle is lower than the upper limit of the target value P1H, in Act 9, the CPU 71 determines whether or not the driving voltage V+ of the first circulation pump 33 is equal to or greater than the maximum adjustment value Vmax, that is, exceeds the adjustable range of the first circulation pump 33. When the driving voltage V+ of the first circulation pump 33 is equal to or greater than the maximum adjustment value Vmax (Yes in Act 9), in Act 10, the CPU 71 increases the ink pressure in the nozzle by decreasing the driving voltage of the second circulation pump. When the driving voltage V+ of the first circulation pump 33 is less than the maximum adjustment value Vmax and is within the adjustable range (No in Act 9), in Act 11, the CPU 71 increases the ink pressure in the nozzle by increasing the driving voltage of the first circulation pump 33.
In Act 8, when the ink pressure Pn of the nozzle exceeds the upper limit of the target value P1H (Yes in Act 8), in Act 12, the CPU 71 determines whether or not the driving voltage V− of the second circulation pump 36 is equal to or greater than the maximum adjustment value Vmax, that is, exceeds the adjustment range of the second circulation pump 36. When the driving voltage V− of the second circulation pump 36 is equal to or greater than the maximum adjustment value Vmax (Yes in Act 12), in Act 13, the CPU 71 decrease the ink pressure in the nozzle by decreasing the driving voltage of the first circulation pump 33. When the driving voltage V− of the second circulation pump 36 is less than the maximum adjustment value Vmax and is within the adjustable range (No in Act 12), in Act 14, the CPU 71 decreases the ink pressure in the nozzle by increasing the driving voltage of the second circulation pump 36.
In Act 15, the CPU 71 performs a feedback control of Act 4 to Act 14 until a circulation end instruction is detected. When a circulation end instruction is detected by a command from the host computer 13 (Yes in Act 15), the CPU 71 controls the opening and closing valve 37 closing to seal the intermediate tank 32 (Act 16). The CPU 71 controls the first circulation pump 33 and the second circulation pump 36 stopping to end the circulation process (Act 17).
The liquid ejection apparatus 10 described above detects an upstream pressure and a downstream pressure of the liquid ejection head 20, and performs the feedback control of the pressure on the first circulation pump 33 and the second circulation pump 36. Thus, the ink pressure in the nozzle can be maintained at an appropriate level. Therefore, for example, even when a pump degrades in quality over time, an appropriate pressure control can be realized.
In the liquid ejection apparatus 10, since the piezoelectric pump 60 is used as the circulation pumps 33 and 36, a structure can be simple and material selection can be easy. The piezoelectric pump 60 does not require a large driving source such as a motor or a solenoid, and thus the size of the piezoelectric pump 60 can be smaller than that of a general diaphragm pump, a piston pump, or a tube pump. Further, for example, when a tube pump is used, there is a possibility that the tube and the ink come into contact with each other, and thus it is necessary to select a material that does not cause deterioration of the tube or the ink. However, when the piezoelectric pump 60 is used, the material selection can be easy. For example, liquid-contact components of the piezoelectric pump 60 may be SUS 316L, PPS, PPA, or polyimide having excellent chemical resistance.
In the first embodiment, the upstream first circulation pump 33 can increase pressure when the driving voltage increases, and decrease pressure when the driving voltage decreases. The downstream second circulation pump 36 can decrease pressure when the driving voltage increases, and increase pressure on the nozzle when the driving voltage decreases. Thus, when the driving voltage exceeds the adjustable range of one circulation pump, the circulation pump on the other side can be used. Therefore, a high-precision control can be realized. Further, the first circulation pump 33, the second circulation pump 36, the supply pump 53, the pressure sensors 39a and 39b, the liquid level sensor 54, the control board, and functions which are required for controlling ink supply, ink circulation, and ink pressure adjustment are integrated in the circulation device 30. Therefore, as compared with a large-sized stationary type circulation device, it is possible to simplify connection of the flow path and electrical connection between a main body of the ink jet recording apparatus 1 and the carriage 11a. Therefore, it is possible to reduce the size, the weight, and the cost of the ink jet recording apparatus 1.
Since the components required for the feedback control are integrated on the control board in the liquid ejection apparatus 10, only information data such as an operation instruction or a state notification that does not require such a high-speed response passes through the communication interface 73. Thus, it is also possible that a requirement for a data transfer rate of the communication interface 73 can be relaxed.
Hereinafter, a liquid ejection apparatus 10A according to a second embodiment will be described with reference to FIG. 7.
As illustrated in
The configuration of the liquid circulation devices according to the above-described embodiments is not limited. The liquid ejection apparatuses 10 and 10A can eject a liquid other than an ink, for example, a liquid including conductive particles for forming a wiring pattern of a printed wiring board, or the like may be used.
The liquid ejection head 20 may have a structure which ejects ink droplets by deforming the diaphragm using static electricity, or a structure which ejects ink droplets from a nozzle using thermal energy of a heater or the like, in addition to the above-described structures.
In the above-described embodiments, an example in which the liquid ejection apparatus is used in the ink jet recording apparatus 1 is described. However, the liquid ejection apparatus is not limited thereto. For example, the liquid ejection apparatus may be used for 3D printers, industrial manufacturing machines, and medical applications. In this case, the size, the weight, and the cost of the apparatus may be reduced.
As the first circulation pump 33, the second circulation pump 36, and the supply pump 53, for example, a tube pump, a diaphragm pump, a piston pump, or the like may be used in place of the piezoelectric pump 60.
In the first embodiment, an example is described in which separation films 32a, 34a, and 35a are respectively formed on a liquid surface in the intermediate tank 32, the upstream tank 34, and the downstream tank 35. However, the liquid ejection apparatus is not limited thereto, and the separating films 32a, 34a, and 35a may be omitted. For example, in some embodiments, there may not be a separation film formed on a liquid surface of the intermediate tank 32, as shown in
In the first embodiment, an example in which the intermediate tank 32 has an opening and closing valve 37a, and the downstream tank 35 has an opening and closing valve 37b is described. However, the liquid ejection apparatus is not limited thereto. For example, in some embodiments, the upstream tank 34 may have an opening and closing valve 37c, controlled by the controller 38.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of the inventions. Indeed, the novel embodiments described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions and changes in the form of the embodiments described herein may be made without departing from the spirit of the inventions. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the inventions.
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|---|---|---|---|
| 2016-178773 | Sep 2016 | JP | national |
| 2017-143838 | Jul 2017 | JP | national |
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| Number | Date | Country | |
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