1. Field of the Invention
The present invention relates to a liquid discharge head which discharges a liquid, a cleaning method for the liquid discharge head, a liquid discharge apparatus, and a substrate for the liquid discharge head.
2. Description of the Related Art
An ink jet head as a typical example of a liquid discharge head includes a plurality of discharge ports for discharging ink, a flow path in communication with the plurality of discharge ports, and an electro-thermal conversion element serving as a thermal energy generation element that generates thermal energy for causing the ink to discharge. The electro-thermal conversion element includes a heat generating resistor, and an electrode for supplying power thereto. An insulation protection layer having electrical insulation properties covers the electro-thermal conversion element, thereby ensuring insulation between the ink and the electro-thermal conversion element. The electro-thermal conversion element is driven to generate thermal energy that rapidly heats the ink to generate bubbles at an ink contact portion (thermal action portion) located above the electro-thermal conversion element, so that the ink is discharged and recording can be executed on a recording medium.
At that time, the thermal action portion of the ink jet head is affected by physical action such as impact arising from cavitation caused by generation and contraction of bubbles, or chemical action caused by the ink. In order to protect the electro-thermal conversion element from the above-described effects, the electro-thermal conversion element is provided with an upper protection layer (upper protection film) made of a metallic material such as a tantalum (Ta) film or a platinum group film (i.e., iridium (Ir) or ruthenium (Ru) film), each of which has relatively strong resistance to the impact arising from the cavitation and the chemical action caused by the ink.
In the thermal action portion which is a contact portion with the ink, a phenomenon occurs in which an additive substance such as a color material included in the ink is decomposed by being heated at high temperature to turn into a low soluble substance and then physically adsorbed onto a surface of the upper protection layer. The above phenomenon is known as “kogation”. If a kogation is formed on the thermal action portion of the upper protection layer as described above, thermal conduction from the thermal action portion to the ink becomes uneven, and generation of bubbles becomes unstable. Therefore, the ink discharge characteristics may be affected thereby.
As a method for solving the above issue, Japanese Patent Application Laid-Open No. 2008-105364 discusses a method for removing a kogation from the thermal action portion, in which an upper protection layer is provided to serve as an electrode for causing an electro-chemical reaction with ink so that a surface of the upper protection layer is eluted into the ink by the electro-chemical reaction. Specifically, in order to remove the kogation, a voltage is applied in such a way that the upper protection layer having the thermal action portion serves as an anode electrode, while an electrode arranged in a region other than the region of the thermal action portion within the same ink flow path serves as a cathode electrode.
According to an aspect of the present invention, a liquid discharge head includes a substrate for the liquid discharge head and a liquid chamber forming member. The substrate for the liquid discharge head includes, a plurality of thermal energy generation elements configured to generate thermal energy for discharging a liquid, an insulation protection layer configured to cover each of the plurality of thermal energy generation elements, and an upper protection film, which is made of a material including at least one of iridium and ruthenium and is disposed corresponding to each of the plurality of thermal energy generation elements, configured to cover at least a region of the insulation protection layer corresponding to each of the plurality of thermal energy generation elements, in this order. The liquid chamber forming member is configured to form, together with the substrate for the liquid discharge head, a liquid chamber in which a plurality of the upper protection films is arranged. In the liquid discharge head, the upper protection film and at least one of the upper protection films adjacent to the upper protection film within the liquid chamber are respectively connected to different external electrodes, and a voltage can be applied therebetween via the different external electrodes.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
In a case where an electrode used for removing (cleaning) a kogation is arranged in the ink flow path as described in Japanese Patent Application Laid-Open No. 2008-105364, the size of the substrate for the ink jet head is increased because a space for arranging the electrode is required.
Therefore, the present invention is directed to suppressing an increase in the size of the liquid discharge head caused by arranging electrodes for cleaning the upper protection film. Various exemplary embodiments, features, and aspects of the invention will be described in detail below with reference to the drawings.
The carriage 500 is driven by a carriage motor 504 attached to the chassis via a timing belt 501. Further, the timing belt 501 is stretched and supported by an idle pulley 503.
When an image is to be formed on a recording medium with the above configuration, a roller pair (not illustrated), including a conveyance roller and a pinch roller, conveys the recording medium to make a positional adjustment with respect to rows. Further, in order to make a positional adjustment with respect to columns, the carriage motor 504 moves the carriage 500 in a direction perpendicular to the above-described conveyance direction to dispose the ink jet head unit 410 on a desired image forming position. The ink jet head 410 to which the positional adjustment has been made discharges ink onto the recording medium while repeating recording main scanning and recording sub-scanning in an alternate manner, so that an image is formed on the recording medium.
Thermal action portions 108 which make contact with ink and apply thermal energy to the ink for causing it to discharge, and independent ink supply ports 121 which supply ink to the thermal action portions 108 are formed on the side of the first surface 111 of the ink jet head substrate 100. Further, a common ink supply port 114 in communication with a plurality of the independent ink supply ports 121 is formed on the side of the second surface 112 of the ink jet head substrate 100. The independent ink supply ports 121 and the common ink supply port 114 penetrate the first surface 111 and the second surface 112 of the ink jet head substrate 100.
An ink flow path (liquid chamber) 120 formed by the ink jet head substrate 100 and the discharge port forming member 122 is disposed on a space between the ink jet head substrate 100 and the discharge port forming member 122, and the plurality of thermal action portions 108 are disposed within the ink flow path 120. Further, on the discharge port forming member 122 formed by a plurality of resin layers laminated to each other, discharge ports 123 are formed at the positions corresponding to the respective thermal action portions 108. The ink that has been supplied from the common ink supply port 114 through the respective independent ink supply ports 121 passes through the ink flow path 120, so as to be supplied to the plurality of thermal action portions 108. The thermal energy causes the ink on the thermal action portions 108 to bubble up, so that the ink is discharged through the discharge ports 123.
The independent ink supply ports 121 are arranged on the spaces between a plurality of the thermal action portions 108 adjacent to each other. Further, as indicated by a dashed line in
In
An upper protection layer (upper protection film) 107 that protects the electro-thermal conversion element 104 from chemical or physical impact arising from heat generation of the electro-thermal conversion element 104 is disposed to cover at least the region of the insulation protection layer 106 that corresponds to the electro-thermal conversion element 104. A portion of the upper protection layer 107 corresponding to the electro-thermal conversion element 104 serves as the thermal action portion 108, and the thermal energy generated by the electro-thermal conversion element 104 is applied to the ink through the thermal action portion 108.
In addition, the upper protection layer 107 is also used as an electrode for removing a kogation formed on the surface of the thermal action portion 108 due to use of the ink jet head 1. In the present exemplary embodiment, metal to be eluted by an electro-chemical reaction in the ink, in particular, iridium (Ir) is used as the upper protection layer 107 that makes contact with the ink. Because Ir has a characteristic of not forming an oxide film in the atmosphere having a temperature up to 800° C., the elution of the upper protection layer 107 into the ink caused by the electro-chemical reaction cannot be interfered even if thermal energy is generated by the electro-thermal conversion element 104 when the ink jet head 1 is in use. In addition, a material other than Ir, such as ruthenium (Ru), an iridium alloy, or a ruthenium alloy may be used for the upper protection layer 107 as long as the material includes at least one of Ir and Ru.
Generally, Ir used for the upper protection layer 107 has low adhesion to the insulation protection layer 106. Therefore, in order to enhance the adhesion between the upper protection layer 107 and the insulation protection layer 106, adhesive layers 109 and 110 serving as intermediate layers, made of a material such as Ta, are disposed between the insulation protection layer 106 and the upper protection layer 107. Further, the adhesive layers 109 and 110 include wiring portions for electrically connecting the upper protection layer 107 to an external electrode, so that a material having electric conductivity is used to form the adhesive layers 109 and 110. The adhesive layers 109 and 110 are inserted into through-holes provided on the insulation protection layer 106, so as to be connected to the electrode wiring layer. A part of the electrode wiring layer forms the external electrodes 113 (see
As illustrated in
Then, in order to remove a kogation from the thermal action portion 108 of the upper protection layer 107a, the upper protection layer 107b adjacent to the upper protection layer 107a is used as the other electrode. In other words, a voltage applying unit 514 disposed on the recording apparatus main unit applies a voltage through the external electrodes in such a way that the upper protection layer 107a serves as an anode electrode while the upper protection layer 107b serves as a cathode electrode. With this configuration, an electro-chemical reaction occurs between the ink and the upper protection layer 107a, so as to remove the kogation by causing a surface of the upper protection layer 107a to be eluded into the ink together with the kogation. Thereafter, a voltage is applied by reversing the polarities of the upper protection layers 107a and 107b, so that the surface of the upper protection layer 107b is eluded into the ink together with the kogation, and thus the kogation thereon is also removed.
As described above, since the adjacent upper protection layers 107a and 107b are in communication with each other within the ink flow path 120, the upper protection layers 107a and 107b can mutually serve as the electrodes for removing a kogation. In the present exemplary embodiment, a wall having a surface in a direction intersecting with the arrangement direction of the upper protection layers 107a and 107b is not disposed between the upper protection layers 107a and 107b. Other configuration may be applicable as long as each of the upper protection layers 107a and 107b can mutually serve as the electrodes for removing a kogation. Therefore, a filter for catching foreign particles may be disposed on a region between the upper protection layers 107a and 107b, for example.
As described above, according to the present exemplary embodiment, the adjacent upper protection layers 107a and 107b, disposed within the same ink flow 120, are respectively connected to different external electrodes. Then, in order to remove a kogation from the upper protection layer 107a, the upper protection layer 107b is used as an electrode for removing the kogation. Accordingly, an electrode dedicated for removing a kogation does not have to be disposed within the ink flow path 120, and thus the upsizing of the ink jet head substrate 100 can be suppressed.
With the above configuration, a decrease in the number of substrates produced from a wafer caused by an increase in the size of the ink jet head substrate 100 is suppressed, and thus the production cost of the ink jet head 1 can be prevented from being increased. In a case where an electrode dedicated for removing a kogation is disposed on the space between the independent ink supply port 121 and the thermal action portion 108, the distance between the independent ink supply port 121 and the thermal action portion 108 is longer, which causes an increase in the ink-supplying time, resulting in lowering the discharge performance of the ink jet head 1. However, with the above-described configuration, lowering the discharge performance of the ink jet head 1 caused thereby can be prevented.
Further, in the present exemplary embodiment, as illustrated in
Further, according to the present exemplary embodiment, a single electro-thermal conversion element 104 is disposed for a single discharge port 123. However, the configuration may be such that a plurality of the electro-thermal conversion elements 104 is provided for a single discharge port 123. In this configuration, the adjacent upper protection layers 107 disposed within the ink flow path 120 can also mutually serve as the electrodes for removing a kogation, as described above.
In the present exemplary embodiment, the arrangement configuration of the upper protection layers 107 and the adhesive layers 109 and 110 are different from that described in the first exemplary embodiment. In the first exemplary embodiment, a plurality of the upper protection layers 107 is alternately connected to different adhesive layers 109 and 110 in the arrangement direction of the upper protection layers 107 within the ink flow path 120. On the other hand, in the present exemplary embodiment, of the two upper protection layers 107b disposed on both sides of the upper protection layer 107a within the ink flow path 120, one upper protection layer 107b is connected to the external electrode that is different from that connected to the upper protection layer 107a, whereas the other upper protection layer 107b is connected to the external electrode that is the same as that connected to the upper protection layer 107a.
Therefore, in the present exemplary embodiment, with respect to any of the upper protection layers 107 disposed within the same ink flow path 120, an upper protection layer 107 connected to a different external electrode is disposed on only one side thereof. Accordingly, a kogation can be equally removed from any of the upper protection layers 107, and thus cleaning of the ink jet head 1 can be performed more stably.
In the present exemplary embodiment, in addition to the configuration described in the first exemplary embodiment, electrodes 117 dedicated for removing a kogation are disposed on the positions adjacent to the upper protection layers 107b disposed on the end portions in the arrangement direction of the upper protection layers 107 within the ink flow paths 120. As illustrated in
As described above, in the present exemplary embodiment, the upper protection layer 107 connected to a different external electrode, or the electrode 117 dedicated for removing a kogation is disposed on both sides of each of the upper protection layers 107. Accordingly, a kogation can be equally removed from any of the upper protection layers 107, and thus cleaning of the ink jet head 1 can be performed more stably.
According to the exemplary embodiment of the present invention, it is possible to suppress an increase in the size of the liquid discharge head caused by arranging electrodes for cleaning the upper protection films.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2013-081552 filed Apr. 9, 2013, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2013-081552 | Apr 2013 | JP | national |