Patent Grant
7661781
1. Field of the Invention
The present invention relates to a liquid ejection head and an image forming apparatus, and more particularly, to a liquid ejection head having a liquid flow channel (nozzle flow channel) of which at least one wall surface is constituted by an elastic member.
2. Description of the Related Art
In the related art, an inkjet recording apparatus is known which includes a liquid ejection head (hereinafter referred simply to as “head”) having a plurality of nozzles, and which records images onto a recording medium by ejecting ink droplets from the nozzles toward the recording medium. One type of head is, for example, a piezoelectric type which pressurizes ink inside pressure chambers through the deformation of actuators, which are typically piezoelectric elements, thereby ejecting droplets of the ink from nozzles connected to the pressure chambers.
In recent years, there have been demands for recording images of high resolution and high definition at high speed, and hence the development of heads capable of ejecting very small droplets of high-viscosity inks having various additional functions has become necessary. However, if it is sought to eject very small droplets (for example, approximately 0.5 pl (picoliters) each) of ink having high-viscosity (for example, approximately 5 to 10 cP (centipoises)) with the piezoelectric type head in the related art, then various problems such as the following arise.
In a piezoelectric type head in the related art, a phenomenon (commonly called “trailing”) is liable to occur in which an ink droplet ejected from a nozzle forms a column shape trailing behind during its flight, and very small ink droplets (hereinafter referred to as “satellite droplets”) following the main ink droplet are thereby generated. The satellite droplets are deposited on the recording medium and lead to a decline in image quality. In order to prevent the generation of the satellite droplets, in Japanese Patent Application Publication No. 7-76087, for example, an ink droplet is ejected by switching the rates of drive voltage change of the actuator in two stages. However, in cases of increased viscosity of the ink, the ink column becomes longer and velocity distribution inside the ink column also becomes scattered, leading to the possible generation of a large number of satellite droplets. Moreover, if the ink droplet intendedly ejected from the nozzle is made very small in size, then the ink column itself becomes narrower, and satellite droplets become more liable to be generated, due to the effect of the Rayleigh-Taylor instability. Therefore, when ejecting a very small droplet of ink having high viscosity, it is difficult to prevent the occurrence of the trailing phenomenon, even if the actuator drive voltage is controlled in the method as disclosed in Japanese Patent Application Publication No. 7-76087.
In order to enable the ejection of high-viscosity ink, it is necessary to raise the power of the actuators, for instance, by increasing the number of layers of laminated piezoelectric body, or by raising the drive voltage; however, both manners have their limits on raising the power of the actuators. Moreover, there is also the problem of reduced ejection frequency due to delays in refilling.
In order to enable the ejection of very small droplets, it is also necessary to raise the drive frequency of the actuators. In a piezoelectric type head according to the related art, ejection is carried out by using what is known as full system resonance, whereby ink is ejected by controlling the drive frequency of the actuators in such a manner that the drive frequency substantially coincides with the resonance frequency of the ink inside the head (i.e., inside pressure chambers). Therefore, in order to increase the drive frequency of the actuators, it is necessary to increase the resonance frequency of the pressure chambers by reducing the size (volume) of the pressure chambers, and this leads to major restrictions on the design of the head.
As described above, in the piezoelectric type heads according to the related art, various problems arise when very small droplets of ink having high viscosity are sought to be ejected, and therefore it has been extremely difficult to achieve ejection of fine droplets of ink having high viscosity.
The present invention has been contrived in view of the foregoing circumstances, an object thereof being to provide a liquid ejection head and an image forming apparatus whereby very small droplets of liquid having high viscosity can be ejected, and desirable image quality can be achieved.
In order to attain the aforementioned object, the present invention is directed to a liquid ejection head, comprising: a liquid flow channel of which at least one wall is constituted by an elastic member; a nozzle which is provided at an end of the liquid flow channel; and a pressure generating device which generates a pressure pulse wave in liquid inside the liquid flow channel, wherein the liquid flow channel and the pressure generating device are composed in such a manner that the pressure pulse wave propagates as a soliton through the liquid in the liquid flow channel.
According to this aspect of the present invention, it is possible to make the pressure pulse wave efficiently propagate as the soliton through the liquid in the liquid flow channel, and moreover, it is possible to create a droplet of the liquid while preventing excessive growth of the liquid column, due to the soliton breaking at the nozzle located at the end of the liquid flow channel. Consequently, it is possible to eject very small droplets of liquid having high viscosity from the nozzle, and therefore desirable image quality can be achieved.
Preferably, the liquid flow channel is formed in a substantially cylindrical shape; and the liquid flow channel and the pressure generating device are composed in such a manner that the following relationships are satisfied:
where w is a full-width at half-maximum of the pressure pulse wave propagating through the liquid in the liquid flow channel, v is a speed of the pressure pulse wave, a is a radius of the liquid flow channel, h is a thickness of the wall of the liquid flow channel, r0 is a maximum amplitude of the pressure pulse wave, ρR is a density of the wall of the liquid flow channel, ρ0 is a density of the liquid in the liquid flow channel, and E is a Young's modulus of the wall of the liquid flow channel.
Preferably, the liquid ejection head in the present invention further comprises: a liquid flow channel forming member which has a groove serving as the liquid flow channel, wherein the elastic member is arranged on a surface of the liquid flow channel forming member on which the groove is formed.
Thereby, the structure is simplified and excellent manufacturability is obtained.
In order to attain the aforementioned object, the present invention is also directed to an image forming apparatus including a liquid ejection head, comprising: a liquid flow channel of which at least one wall is constituted by an elastic member; a nozzle which is provided at an end of the liquid flow channel; and a pressure generating device which generates a pressure pulse wave in liquid inside the liquid flow channel, wherein the liquid flow channel and the pressure generating device are composed in such a manner that the pressure pulse wave propagates as a soliton through the liquid in the liquid flow channel.
According to the present invention, it is possible to make a pressure pulse wave efficiently propagate as a soliton through liquid in a liquid flow channel, and furthermore, it is possible to create a droplet of the liquid while preventing excessive growth of the liquid column, due to the soliton breaking at the nozzle section located at an end of the liquid flow channel. Consequently, it is possible to eject very small droplets of liquid having high viscosity from the nozzle, and therefore desirable image quality can be achieved.
The nature of this invention, as well as other objects and benefits thereof, will be explained in the following with reference to the accompanying drawings, in which like reference characters designate the same or similar parts throughout the figures and wherein:
In
In the case of a configuration in which roll paper is used, a cutter 28 is provided as shown in
In the case of a configuration in which a plurality of types of recording paper can be used, it is preferable that an information recording medium such as a bar code and a wireless tag containing information about the type of paper is attached to the magazine, and by reading the information contained in the information recording medium with a predetermined reading device, the type of paper to be used is automatically determined, and ink-droplet ejection is controlled so that the ink-droplets are ejected in an appropriate manner in accordance with the type of paper.
The recording paper 16 delivered from the paper supply unit 18 retains curl due to having been loaded in the magazine. In order to remove the curl, heat is applied to the recording paper 16 in the decurling unit 20 by a heating drum 30 in the direction opposite from the curl direction in the magazine. The heating temperature at this time is preferably controlled so that the recording paper 16 has a curl in which the surface on which the print is to be made is slightly round outward.
The decurled and cut recording paper 16 is delivered to the suction belt conveyance unit 22. The suction belt conveyance unit 22 has a configuration in which an endless belt 33 is set around rollers 31 and 32 so that the portion of the endless belt 33 facing at least the nozzle face of the printing unit 12 and the sensor face of the print determination unit 24 forms a plane.
The belt 33 has a width that is greater than the width of the recording paper 16, and a plurality of suction apertures (not shown) are formed on the belt surface. A suction chamber 34 is disposed in a position facing the sensor surface of the print determination unit 24 and the nozzle surface of the printing unit 12 on the interior side of the belt 33, which is set around the rollers 31 and 32, as shown in
The belt 33 is driven in the clockwise direction in
Since ink adheres to the belt 33 when a marginless print job or the like is performed, a belt-cleaning unit 36 is disposed in a predetermined position (a suitable position outside the printing area) on the exterior side of the belt 33. Although the details of the configuration of the belt-cleaning unit 36 are not shown, embodiments thereof include a configuration of nipping with cleaning rollers with a brush roller and a water absorbent roller, an air blow configuration in which clean air is blown, or a combination of these. In the case of the configuration in which the belt 33 is nipped with the cleaning rollers, it is preferable to make the line velocity of the cleaning rollers different than that of the belt 33 to improve the cleaning effect.
The inkjet recording apparatus 10 can comprise a roller nip conveyance mechanism, instead of the suction belt conveyance unit 22. However, there is a drawback in the roller nip conveyance mechanism that the print tends to be smeared when the printing area is conveyed by the roller nip action because the nip roller makes contact with the printed surface of the paper immediately after printing. Therefore, the suction belt conveyance in which nothing comes into contact with the image surface in the printing area is preferable.
A heating fan 40 is disposed on the upstream side of the printing unit 12 in the conveyance pathway formed by the suction belt conveyance unit 22. The heating fan 40 blows heated air onto the recording paper 16 to heat the recording paper 16 immediately before printing so that the ink deposited on the recording paper 16 dries more easily.
The print unit 12 is a so-called “full line head” in which a line head having a length corresponding to the maximum paper width is arranged in a direction (main scanning direction) that is perpendicular to the paper conveyance direction (sub-scanning direction). The heads 12K, 12C, 12M, and 12Y forming the print unit 12 are constituted by line heads in which ink ejection ports (nozzles) are arranged through a length exceeding at least one edge of the maximum size recording paper 16 intended for use with the inkjet recording apparatus 10.
The heads 12K, 12C, 12M, and 12Y corresponding to respective ink colors are disposed in the order, black (K), cyan (C), magenta (M), and yellow (Y), from the upstream side (the left-hand side in
The print unit 12, in which the full-line heads covering the entire width of the paper are thus provided for the respective ink colors, can record an image over the entire surface of the recording paper 16 by performing the action of moving the recording paper 16 and the print unit 12 relative to each other in the paper conveyance direction (sub-scanning direction) just once (in other words, by means of a single sub-scan). Higher-speed printing is thereby made possible and productivity can be improved in comparison with a shuttle type head configuration in which a head moves reciprocally in a direction (main scanning direction) that is perpendicular to the paper conveyance direction.
Although the configuration with the KCMY four standard colors is described in the present embodiment, combinations of the ink colors and the number of colors are not limited to those. Light inks or dark inks can be added as required. For example, a configuration is possible in which heads for ejecting light-colored inks such as light cyan and light magenta are added.
As shown in
The print determination unit 24 has an image sensor (line sensor) for capturing an image of the ink-droplet deposition result of the printing unit 12, and functions as a device to check for ejection defects such as clogs of the nozzles from the ink-droplet deposition results evaluated by the image sensor.
The print determination unit 24 of the present embodiment is configured with at least a line sensor having rows of photoelectric transducing elements with a width that is greater than the ink-droplet ejection width (image recording width) of the heads 12K, 12C, 12M, and 12Y. This line sensor has a color separation line CCD sensor including a red (R) sensor row composed of photoelectric transducing elements (pixels) arranged in a line provided with an R filter, a green (G) sensor row with a G filter, and a blue (B) sensor row with a B filter. Instead of a line sensor, it is possible to use an area sensor composed of photoelectric transducing elements which are arranged two-dimensionally.
The print determination unit 24 reads a test pattern image printed by the heads 12K, 12C, 12M, and 12Y for the respective colors, and the ejection of each head is determined. The ejection determination includes the presence of the ejection, measurement of the dot size, and measurement of the dot deposition position.
A post-drying unit 42 is disposed following the print determination unit 24. The post-drying unit 42 is a device to dry the printed image surface, and includes a heating fan, for example. It is preferable to avoid contact with the printed surface until the printed ink dries, and a device that blows heated air onto the printed surface is preferable.
In cases in which printing is performed with dye-based ink on porous paper, blocking the pores of the paper by the application of pressure prevents the ink from coming into contact with ozone and other substance that cause dye molecules to break down, and has the effect of increasing the durability of the print.
A heating/pressurizing unit 44 is disposed following the post-drying unit 42. The heating/pressurizing unit 44 is a device to control the glossiness of the image surface, and the image surface is pressed with a pressure roller 45 having a predetermined uneven surface shape while the image surface is heated, and the uneven shape is transferred to the image surface.
The printed matter generated in this manner is outputted from the paper output unit 26. The target print (i.e., the result of printing the target image) and the test print are preferably outputted separately. In the inkjet recording apparatus 10, a sorting device (not shown) is provided for switching the outputting pathways in order to sort the printed matter with the target print and the printed matter with the test print, and to send them to paper output units 26A and 26B, respectively. When the target print and the test print are simultaneously formed in parallel on the same large sheet of paper, the test print portion is cut and separated by a cutter (second cutter) 48. The cutter 48 is disposed directly in front of the paper output unit 26, and is used for cutting the test print portion from the target print portion when a test print has been performed in the blank portion of the target print. The structure of the cutter 48 is the same as the first cutter 28 described above, and has a stationary blade 48A and a round blade 48B.
Although not shown in drawings, the paper output unit 26A for the target prints is provided with a sorter for collecting prints according to print orders.
Next, the composition of the heads 12K, 12C, 12M, and 12Y is described. The heads 12K, 12C, 12M, and 12Y of the respective ink colors have the same composition, and a reference numeral 50 is hereinafter used to designate a representative embodiment of the heads.
As shown in
The piezoelectric actuator 56 is constituted by a flat plate-shaped piezoelectric body 64, and individual electrodes 66 and a common electrode 68, which are respectively arranged on opposite surfaces of the piezoelectric body 64. The individual electrode 66 is provided for each nozzle 51 (i.e., for each nozzle flow channel 58), and is disposed on the surface of the piezoelectric body 64 reverse to the surface adjacent to the common flow channel 60, in a position opposing each nozzle flow channel 58. The common electrode 68 is formed over the whole of the surface of the piezoelectric body 64 on the side adjacent to the common flow channel 60. An insulating protective film (not shown) of resin, or the like, is formed on the surface of the common electrode 68, thereby preventing the common electrode 68 from coming in contact with the ink accumulated inside the common flow channel 60.
The region of the piezoelectric body 64 interposed between each individual electrode 66 and the common electrode 68 forms a displacement generating unit 70, which generates a prescribed displacement when a voltage is applied between the corresponding individual electrode 66 and the common electrode 68. In the present embodiment, a composition is adopted in which the common electrode 68 is grounded at a position not shown in
One of characteristic features in the present invention is that the nozzle flow channels 58 and the piezoelectric actuators 56 are constituted in such a manner that the pressure pulse waves propagate as solitons through the liquid (ink) in the nozzle flow channels 58. It is thus possible to eject very small droplets of high-viscosity ink while preventing the phenomenon of trailing, more specifically, the occurrence of satellite droplets.
Specific conditions of the composition of the nozzle flow channels 58 and the piezoelectric actuators 56 are described below.
where w is the full-width at half-maximum (FWHM) of the pressure pulse wave, {tilde over (v)} is the speed of the pressure pulse wave, a is the radius of the nozzle flow channel 58, h is the thickness of a wall 59 of the nozzle flow channel 58, {tilde over (ρ)}R is the density of the nozzle flow channel wall 59, r0 is the maximum amplitude of the pressure pulse wave, {tilde over (ρ)}0 is the density of the liquid (ink) in the nozzle flow channel 58, and {tilde over (E)}{tilde over ( )}is the Young's modulus of the nozzle flow channel wall 59. Here, the variables capped with the symbol “{tilde over ( )}” are known quantities, and the other variables are unknown quantities.
In this case, the volume {tilde over (V)}{tilde over ( )} of a droplet of the liquid ejected is assumed to be expressed as:
{tilde over (V)}≅π(a+r0)2w. (3)
Moreover, the full-width at half-maximum w of the pressure pulse wave is assumed to be approximately equal to the diameter of the ejected droplet of the liquid, in other words, the volume of the ejected droplet is assumed as:
Here, the known quantities shown in the following Table 1 are used for calculation.
By solving the above-described formulas (1) to (4) for the unknown quantities with the known quantities in Table 1, the results shown in the following Table 2 are obtained. Here, the formulas (3) and (4) are assumed to be equations.
Hence, if using the piezoelectric actuator 56 (for example, an ultrasonic element) that satisfies drive conditions where the pressure pulse wave propagating through the liquid in the nozzle flow channel 58 has a velocity v of 1500 m/s, then by composing the nozzle flow channel forming substrate 52 from a material having the bending rigidity equivalent of stainless steel, and by setting the thickness h of the nozzle flow channel wall 59 to 8 μm and the radius of the nozzle flow channel 58 to 1.8 μm, it is possible to make the pressure pulse wave introduced into the nozzle flow channel 58 propagate with good efficiency in the form of a soliton having the full-width at half-maximum of 10 μm, and the soliton breaking at the nozzle 51 positioned at the end of the nozzle flow channel 58 leads to the generation of a droplet of the liquid (ink) having the volume of approximately 0.5 pl, while preventing excessive growth of the liquid column.
Moreover, if the ejection frequency is taken to be f, then the period at which the pressure pulse waves are outputted in order to trigger the solitons is T=1/f. If the outputted pressure pulse wave (soliton) reaches the nozzle 51 at the end of the nozzle flow channel 58 within this period, then there is a possibility that the reflection of this preceding soliton reflected at the nozzle will collide with the subsequent soliton in the nozzle flow channel 58. Hence, although there is little interaction between solitons colliding with each other, it is desirable to adopt a design that avoids the coexistence of a plurality of solitons in the nozzle flow channel 58, in order to prevent as far as possible any reduction in the propagation speed of the solitons. That is, it is desirable that the flow channel length L of the nozzle flow channel 58 (see
For example, in a case where the ejection frequency f is 100 kHz, it is desirable that the flow channel length L of the nozzle flow channel 58 is not longer than 7.5 mm, in accordance with the inequality (5).
According to the first embodiment, by composing the nozzle flow channels 58 and the piezoelectric actuators 56 so as to satisfy the above-described relationships (1) to (4), it is possible to make the pressure pulse waves efficiently propagate as solitons through the liquid (ink) in the nozzle flow channels 58. Furthermore, since the soliton is used and therefore the liquid region carrying the momentum is localized, it is possible to achieve a very small droplet size when a droplet of the liquid is formed, and it is possible to reduce the trailing phenomenon caused by excessive growth of the liquid column. Consequently, it is possible to prevent the occurrence of satellite droplets and to eject a very small droplet of high-viscosity liquid from the nozzle, and hence a desirable image quality can be achieved.
In the head 50 according to the present embodiment, it is not necessary to make the drive frequency of the piezoelectric actuators 56 coincide with the resonance frequency of the liquid (ink) inside the head 50. Hence, driving at the resonance frequency of the piezoelectric actuators 56 themselves becomes possible, and higher-frequency ejection can be achieved in comparison with a piezoelectric head in the related art. In particular, since highly efficient propagation is achieved due to the soliton effect and the streaming effect (the effect of pushing the liquid through the radiated pressure) created by using a frequency in the ultrasonic range, then it is possible to improve refilling characteristics in cases where ink of high viscosity is used.
The first embodiment is described as the embodiment in which nozzle flow channels 58 are arranged in one row following the lengthwise direction of the head 50, but there is also a mode in which the nozzle flow channels 58 are arranged in a plurality of rows.
Next, a second embodiment of the present invention is described. Below, the parts of the second embodiment common to the first embodiment described above are not described, and the explanation focuses on the characteristic features of the second embodiment.
According to the second embodiment, although the propagation characteristics of the pressure pulse waves through the liquid in the nozzle flow channels 58 are slightly inferior to the first embodiment, it is still possible to eject very small droplets of high-viscosity liquid from the nozzles 51 while preventing the trailing phenomenon. In particular, in the second embodiment, by adopting the mode in which one wall of the nozzle flow channels 58 is constituted by the elastic member 76, the structure is simplified and the composition having even better manufacturability is obtained.
In the present embodiment, the mode is described in which one wall of the nozzle flow channels 58 is constituted by the elastic member 76, but the implementation of the present invention is not limited to this. For example, in a modification embodiment of the second embodiment, it is also possible to compose both of the opposing walls of the nozzle flow channels 58 from elastic members 76 (76A and 76B), as in a head 150′ shown in
Furthermore, although not shown in
It should be understood, however, that there is no intention to limit the invention to the specific forms disclosed, but on the contrary, the invention is to cover all modifications, alternate constructions and equivalents falling within the spirit and scope of the invention as expressed in the appended claims.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2006-012750 | Jan 2006 | JP | national |
| Number | Name | Date | Kind |
|---|---|---|---|
| 5453767 | Chang et al. | Sep 1995 | A |
| 6481073 | Sugahara | Nov 2002 | B1 |
| Number | Date | Country |
|---|---|---|
| 7-76087 | Mar 1995 | JP |
| Number | Date | Country | |
|---|---|---|---|
| 20070171244 A1 | Jul 2007 | US |
