Patent Grant
6848764
The present invention relates to a method and apparatus for operating heaters of a print head in a continuous ink jet to provide a stream of ink droplets. In particular, the present invention relates to a method and apparatus for generating a pulsetrain to operate the heaters of the print head to allow variation in pulse width and/or pulse period.
Ink jet printing has become recognized as a prominent contender in the digitally controlled, electronic printing arena because of various advantages such as its non-impact, low noise characteristics and system simplicity. For these reasons, ink jet printers have achieved commercial success for home and office use and other areas.
Traditionally, color ink jet printing is accomplished by one of two technologies, referred to as drop-on-demand and continuous stream printing. Both technologies require independent ink supplies for each of the colors of ink provided. Ink is fed through channels formed in the print head. Each channel includes a nozzle from which droplets of ink are selectively extruded and deposited upon a medium. Each technology requires separate ink delivery systems for each ink color used in printing. Ordinarily, the three primary subtractive colors, i.e. cyan, yellow and magenta, are used because these colors can produce up to several million perceived color combinations.
In drop-on-demand ink jet printing, ink droplets are generated for impact upon a print medium using a pressurization actuator (thermal, piezoelectric, etc.). Selective activation of the actuator causes the formation and ejection of an ink droplet that crosses the space between the print head and the print medium and strikes the print medium. The formation of printed images is achieved by controlling the individual formation of ink droplets as the medium is moved relative to the print head.
In continuous stream or continuous ink jet printing, a pressurized ink source is used for producing a continuous stream of ink droplets. Conventional continuous ink jet printers utilize electrostatic charging devices that are placed close to the point where a filament of working fluid breaks into individual ink droplets. The ink droplets are electrically charged and then directed to an appropriate location by deflection electrodes having a large potential difference. When no print is desired, the ink droplets are deflected into an ink capturing mechanism (catcher, interceptor, gutter, etc.) and either recycled or discarded. When printing is desired, the ink droplets are not deflected and allowed to strike a recording medium. Alternatively, deflected ink droplets may be allowed to strike the recording medium, while non-deflected ink droplets are collected in the ink capturing mechanism. While such continuous ink jet printing devices are faster than drop on demand devices and produce higher quality printed images and graphics, the electrostatic deflection mechanism they employ is expensive to manufacture and relatively fragile during operation.
Recently, a novel continuous ink jet printer system has been developed which renders the above-described electrostatic charging devices unnecessary and provides improved control of droplet formation. The system is disclosed in the commonly assigned U.S. Pat. No. 6,079,821 in which periodic application of weak heat pulses to the ink stream by a heater causes the ink stream to break up into a plurality of droplets synchronous with the applied heat pulses and at a position spaced from the nozzle. The droplets are deflected by heat pulses from a heater in a nozzle bore. This is referred to as asymmetrical application of heat pulses. The heat pulses deflect ink drops between a “print” direction (onto a recording medium), and a “non-print” direction (back into a “catcher”).
While such continuous ink jet printers utilizing asymmetrical application of heat have demonstrated many proven advantages over conventional ink jet printers utilizing electrostatic charging tunnels, a cost effective and reliable method and apparatus for controlling the heaters of the ink jet printer is required to ensure proper operation of the ink jet printer. Otherwise, misdirection of the ink droplets may occur which will detriment the print quality.
In view of the foregoing, an advantage of the present invention is in providing a cost effective and reliable method and apparatus for controlling the heaters of the ink jet printer.
Another advantage of the present invention is in providing such a method and apparatus that allows generation of a signal usable for controlling the heaters where the pulse width and/or pulse period of the signal pulses are readily adjustable.
In accordance with one aspect of the present invention, the above noted advantages are attained by a method for generating an electrical signal with a plurality of pulses used to operate a continuous ink jet printer having plurality of nozzles, including the steps of generating a data table with a plurality of segment values, each segment value designating one of a high pulse and a low pulse of the electrical signal, and designating the pulse width of the designated pulse, reading a segment value from the data table, and generating at least one of a high pulse and a low pulse, the generated pulse and pulse width of the generated pulse being designated by the read segment value.
In one embodiment, the present method further includes the step of iteratively reading each of the plurality of segment values from the data table and the step of generating at least one of a high pulse and a low pulse after each segment value is read from the data table, the generated pulse and pulse width being designated by each of the iteratively read segment values. Because each of the segment values can be customized, pulse width of two consecutive high pulses or low pulses may be different from one another.
In another embodiment, the method further includes the step of loading a new plurality of segment values into the data table after the plurality of segment values are iteratively read from the data table. The method may further include the step of converting pulse width designated by each of the iteratively read segment values into time. In addition, the method may further include the step of iteratively designating which segment value is to be read.
In accordance with another embodiment of the present method, the plurality of segment values in the data table designate the high pulse and low pulse in alternating order. In addition, two segment values of the data table that designate two consecutive high or low pulses designate pulses having different pulse widths from one another. The low pulses may be used to delay the generation of the high pulses.
In yet another embodiment of the present method, the number of at least one of the high pulses and the low pulses in the data table is less than the maximum number of graytones of the continuous ink jet printer. The first segment value in the data table designates a high pulse or a low pulse which delays the generation of a first high pulse.
In accordance with another aspect of the present invention, the above noted advantages are attained by a control circuit for generating an electrical signal with a plurality of pulses used to operate a continuous ink jet printer having plurality of nozzles including a memory device adapted to store a data table with a plurality of segment values, each segment value designating one of a high pulse and a low pulse of the electrical signal, and designating the pulse width of the designated pulse, a counter for sequentially counting based on a segment value from the data table to thereby convert the pulse width designated by the segment value into time, and a synchronization device adapted to synchronize the memory device with the counter to allow loading of each of the plurality of segment values from the memory device to the counter.
In accordance with one embodiment, the counter provides a counter output to the synchronization logic and the synchronization logic outputs the electrical signal based on the counter output. In this regard, the synchronization logic may include a state machine and a read address generator that iteratively designates which segment value from the memory device is loaded to the counter by the synchronization device. In various embodiments of the control circuit, the memory device may be a random access memory and the counter may be a count down or a count up counter.
These and other advantages and features of the present invention will become more apparent from the following detailed description of the preferred embodiments of the present invention when viewed in conjunction with the accompanying drawings.
As will be evident from the discussion below, the present invention provides an effective method for controlling the heaters of a print head in a continuous ink jet printer. In this regard, it should initially be noted that whereas the method as applied to a specific example is described, the present invention is not limited thereto but may be applied to other embodiments where the configuration of the printer, print head and/or heaters is different than that shown in the various figures.
Recording medium 18 is moved relative to print head 16 by a recording medium transport system 20 which is electronically controlled by a recording medium transport control system 22 which in turn, is controlled by a micro-controller 24. The recording medium transport system is shown in
Ink is preferably contained in an ink reservoir 28 under pressure. In the nonprinting state, continuous ink jet drop streams are unable to reach recording medium 18 due to an ink gutter 17 that blocks the ink jet drop stream and which may be operated to allow a portion of the ink to be recycled by an ink recycling unit 19. The ink recycling unit 19 reconditions the ink and feeds it back to reservoir 28. Such ink recycling units are well known in the art. The ink pressure suitable for optimal operation will depend on a number of factors, including geometry and thermal properties of the nozzles and thermal properties of the ink. A constant ink pressure can be achieved by applying pressure to ink reservoir 28 under the control of ink pressure regulator 26.
The ink is distributed to the back surface of print head 16 by an ink channel device 30. The ink preferably flows through slots and/or holes etched through a silicon substrate of print head 16 to its front surface where a plurality of nozzles and heaters are situated. Of course, with print head 16 fabricated from silicon, it is possible to integrate heater control circuits 14 with the print head. The mechanics of the generation and deflection of ink droplets of the ink stream is presented in U.S. Pat. No. 6,079,821 described previously and thus, further detail is omitted here. The print head 16 is controlled by the heater control circuits 14 which are operated by the micro-controller 24 in accordance with the present invention discussed below which provide an effective method for controlling the heaters of print head 16.
Of course, in other embodiments, the heater elements may be of any appropriate shape and may have only one heater element which is operated by the control circuit 14 to generate and deflect the ink droplets. However, by providing a second heater element on an opposing side as shown in the present example, a deflection correcting electrical pulse may be provided to the second heater element to correct the deflection of the ink droplet at the end of the print operation to further minimize potential ink droplet misdirection. The details of such operation is provided in U.S. Pat. No. 6,254,225 to Chwalek et al. and need not be present herein.
As can be seen, the first and second heater elements 51a and 51b respectively are connected to a power source 54 and ground 55, the power for the first heater element 51a and the second heater element 51b being turned on and off by driver transistors 56a and 56b respectively. The driver transistors 56a and 56b are engaged by a signal from AND gates 58a and 58b respectively, such signal being provided by each of the AND gates when the “ENABLE” and “LATCHED DATA” signals for the corresponding AND gate is received. When the driver transistors 56a or 56b are engaged, the respective heater element is activated to cause deflection of the ink droplet, again, the heater element 51b being timed by a deflection correcting electrical pulse. Again, in other embodiments, only SIDE 1 having the first heater element 51a may be provided which is operated by the control circuit 14 in the manner described below to generate and deflect the ink droplets.
Electrical pulses or pulsetrains from the control circuit 14 is provided to the first heater element 51a so that the asymmetric application of heat generated on SIDE 1 of the nozzle bore 46 to periodically deflect the ink droplet stream during a printing operation by the heater section 51a. Control circuit 14 may be programmed to supply power to the first heater element 51a of the heater 50 in the form of pulses described in detail below, deflection of an ink droplet occurring whenever an electrical power pulse by the AND gate 58a is provided. In one embodiment, the deflected ink droplets reach the recording medium 18 while the undeflected drops may be blocked from reaching recording medium 18 by a cut-off device such as the ink gutter 17 noted above. In an alternate printing scheme, ink gutter 17 may be placed to block deflected drops so that undeflected drops will be allowed to reach recording medium 18.
The heater elements 51a and 51b of heater 50 may be made of doped polysilicon, although other resistive heater materials could be used. Heater 50 is separated from substrate 42 by thermal and electrical insulating layer (not shown) and the nozzle bore 46 may be etched. The surface of the print head 16 can be coated with a hydro-phobizing layer (not shown) to prevent accidental spread of the ink across the front of the print head 16.
The operation of the first heater elements 51a of the heater 50 on the print head 16 which are actuated to deflect the ink droplets is described herein below so that fuller appreciation of the operation of the second heater elements 51b in accordance with the present invention as discussed later may be attained. In this regard,
To control the large number of heaters, the ink jet print head 16 further includes plurality of electronic serial shift registers 60a on SIDE 1 and serial shift registers on SIDE 2 (not shown), in this case, M serial shift registers per side, to minimize the number of electrical connections between the heater control circuit 14 and the print head 16. Each serial shift register may be 1-bit wide by N-bits long as shown in FIG. 3. Thus, N×M is the total number of heaters per side (SIDE 1 and SIDE 2) in the print head 16. In this regard, in
The SHIFT_CLOCK signal is used to move the digital data value of 1 or 0 present at the HEAD_DATA1 and HEAD_DATA2 signals through the SHIFT REGISTER 1 and SHIFT REGISTER 2 respectively. One bit of data is shifted for each clock pulse per shift register. The serial shift registers are analogous to a bucket brigade, where the contents of a register location (for instance at P) is moved into a subsequent register location (P+1) on the rising edge or other portion of the clock signal. The contents of register location (P−1) is moved into location (P) on this same clock signal. Thus, to fill all N locations of SHIFT REGISTER 1 and SHIFT REGISTER 2 with new data from the HEAD_DATA1 and HEAD_DATA2 signal requires N clock periods in the illustrated embodiment.
In addition to the serial shift registers shown in
As shown in
A second signal, generically referred to as ENABLEx, and in the present example, the ENABLE1 and ENABLE2 signal, is connected in common to the AND gates 58a within each heater group. In this regard, in simple print head configurations, there may be just one heater group where all heaters are connected to one ENABLE signal for the whole print head. In other configurations, especially for larger nozzle count such as the embodiment shown in
Thus, as previously described, for an individual first heater element 51a to be energized to heat one side of the nozzle 40, two conditions must be true in the present embodiment:
When both signals to the AND gate 58a are digital 1, the output of the AND gate 58a is a digital 1 so that the associated driver transistor 56a is turned ON and power is applied to the first heater element 51a. In accordance with the illustrated embodiment, the ENABLEx signal defines the ON time for any first heater element 51a, and the output of the associated latch register 70a controls whether a heater is ON or OFF during a particular printing operation so that the appropriate graytone level L of the continuous G graytones can be attained. In this regard, it should be noted that the maximum number of graytones is referred to herein as G graytones whereas the actual graytone level of a given particular pixel is referred to herein as graytone level L. Thus, in the examples discussed herein below, maximum of 8 graytones are possible (G=8), the graytone levels L being 0, 1, 2 . . . 6, 7. It should be noted that 0 is considered as one of the graytone levels since it represents minimum print density (i.e. no ink) and graytone level 7 is the darkest graytone level. Of course, in other examples, different number of graytone levels are possible as well.
The ENABLE signal is pulsed G-1 times, the ENABLE signal not being pulsed when graytone level is 0 which signifies the minimum density when no printing occurs. In the illustrated example of
Stated in another manner, whereas the ENABLE signal establishes the timing of the operation of the first heater element 51a up to its maximum graytone level, the HEAD_DATA signal determines the actual number of the operation of the first heater element 51a since it is correlated to the image data value. Correspondingly, both of these signals are used to generate the HEATER_DATA pulse train as shown which is used to actuate the first heater element 51a to deflect the continuous ink jet droplets.
The HEAD_DATA signal may be generated in any appropriate manner to practice the present invention as described above. Thus, the details of generating the HEAD_DATA signal is omitted herein. However, one method of generating the HEAD_DATA signal for both the first heater element 51a and second heater element 51b are discussed in detail in pending U.S. patent application Ser. No. 10/172,429, entiled METHOD OF CONTROLLING HEATERS IN A CONTINUOUS INK JET PRINT HEAD HAVING SEGMENTED HEATERS TO PREVENT TERMINAL INK DROP MISDIRECTION commonly assigned to the assignee of the present application, which is incorporated herein by reference.
A generic form of the ENABLE signal waveform/pulsetrain 80 which is used in the manner above described is shown in
Referring again to
It should also be noted that the numeral following the pulse indicator signifies the graytone level to which the generated pulse corresponds, the numeral generically being referred to herein as “x”. Thus, P1 refers to the pulse period corresponding to graytone level 1 whereas Px refers to pulse period in general.
In accordance with the present invention, Hx and Lx can take on any values thereby providing variable pulse width and/or variable pulse period so that the pulsetrain 80 can be totally customized to the particular application and/or print head. Thus, the present invention provides a method for generating the ENABLE signal where each pulse corresponding to each gray level can be adjusted independently and dynamically from one another.
As shown in
The HIGH pulse width segment of each pulse period is the “ON” time of the heater for that particular gray level and may be a digital 1 signal. In other words, the HIGH pulse width segment may be the power pulse utilized to operate a designated heater. In the present example, the pulsetrain 80 is the ENABLE signal provided to an AND gate 58a such that when the HIGH pulse width is provided, the corresponding first heater element 51a is operated when the HEAD_DATA signal is also provided to the AND gate 58a. Of course, in other embodiments, the heater element may be operated directly by the ENABLE signal itself.
In accordance with the example of the present method, the ENABLE signal, i.e. the pulsetrain 80, may be represented in a tabular form in an ENABLE Table having the segment values as listed in Table 1 below. As can be seen, the ENABLE Table designate the high pulse and low pulse in alternating order in the illustrated example. Of course, the actual segment values would be numerically represented instead of the descriptors which are shown below for clarity. The actual numerical values may be calculated in various manners, one of which is further detailed below.
The control circuit 14 is designed to convert the values of TABLE 1 in the ENABLE Table 89, into the appropriate ENABLE signal pulsetrain which is used to allow actuation of a designated heater element in the manner previously described. As can be seen, the control circuit includes memory 86 where the ENABLE Table 89 and the contents thereof are stored, a counter 87 which converts the information in the ENABLE Table into time by counting for the pulse width designated by the segment values of the ENABLE Table, and a synchronization logic 88 that controls the memory 86 and the counter 87 to allow loading of each of the plurality of segment values from the memory device 86 to the counter 87. In the present embodiment, the synchronization logic 88 also generates the ENABLE signal pulsetrain generically shown in
One embodiment for implementing the control circuit 14 of
These components of the control circuit 14 are utilized to execute a sequence of operations over time, based on the ENABLE Table 89 and various inputs to generate the desired pulsetrain to thereby allow actuation of the heater elements as described. Of course, it should be noted that
The sequence of operations for the circuitry of
Since the first digital value of the ENABLE Table of the present example having the values of TABLE 1 contains the pulse width of the first HIGH pulse width segment, the ENABLE signal provided as the output of the State Machine 98 will be asserted to a digital value of 1. As soon as the Counter_Load signal is deasserted, the Count Down Counter 94 counts down in step 108, and the State Machine 98 toggles the ENABLE signal to an opposite polarity in step 110. It should be noted here that step 110 is the first instance of toggling from the Reset state of 0 to a 1. The toggled value remains at 1 until after the Count Down Counter 94 completes step 111 and loops back to step 106 discussed above.
While the Count Down Counter 94 is counting, the State Machine 98 pulses the Read_Address_Clock so that the output of the RAM Read Address Generator 96 is incremented to point to the address of the next value in the ENABLE Table 89 to ready for the next read in step 109. When the State Machine 98 determines that the output of the Count Down Counter 94 is zero as shown in step 111, the State Machine 98 then starts loading in the next ENABLE Table value shown in TABLE 1 into the Count Down Counter 94 and the same sequence of events will be repeated until the last table value of the ENABLE Table is read and loaded into the Count Down Counter 94 as shown in step 112. Then the whole process starts again for the next pixel to be printed by the nozzle 40 of the print head 16. Of course, it should be understood that the above described method is merely one example and the present invention should not be construed to be limited thereto.
Thus, based on the discussion above, it should be evident that the present invention provides a method for generating an electrical signal such as the ENABLE signal with a plurality of pulses used to operate a continuous ink jet printer with a plurality of nozzles. As can now be appreciated, the method includes the steps of generating a data table such as the ENABLE Table described above with a plurality of segment values, each segment value designating one of a high pulse and a low pulse of the electrical signal, and designating the pulse width of the designated pulse, reading a segment value from the data table, and generating at least one of a high pulse and a low pulse, the generated pulse and pulse width of the generated pulse being designated by the read segment value.
In the embodiment specifically shown in
Of course, the present method also provides a significant advantage in that new segment values may be readily loaded into the ENABLE Table so that a different ENABLE signal with different high pulses and low pulses can be readily generated. This provides a cost effective method for adjusting the pulse width and/or pulse period of the signal pulses. Moreover, as also previously described, the method in the described embodiment further includes the step of using the count down counter 94 to convert pulse width designated by each of the iteratively read segment values into time while the RAM Read Address Generator 96 is used to iteratively designate which segment value is to be read.
The actual digital values stored in the ENABLE Table for each segment pulse width which correspond to those shown in TABLE 1 may be calculated using the following formula:
The clock frequency of the Count Down Counter 94 dictates the resolution of the ENABLE signal output by the State Machine 98. Therefore, if higher resolution is desired, a higher clock frequency is required for the Count Down Counter 94. From the above equation, the minimum segment pulse width for the operational steps shown in
As can be seen, the flow diagram 200 shown in
Of course, the above described method is merely one example which can be used to eliminate the effect of Control Logic Overhead and the present invention is not limited thereto. Another method for eliminating the Control Logic Overhead is to add an additional Count Down Counter (not shown) so that while one counter counts the HIGH pulse width segment, the other counter counts the LOW pulse width segment, thus, eliminating the need to wait for reading and loading the next value.
In accordance with the present invention, very specific customizable pulsetrain such as the ENABLE signal, may be generated to control the continuous ink jet print head by using an ENABLE Table coupled with a counter and synchronization logic in the manner described above. One significant advantage of the invention is that it allows for dynamic ENABLE signal generation since the segment values in the ENABLE Table can be changed at any given time by downloading new segment values to the ENABLE Table.
Still another advantage is that the method in accordance with present invention can be readily used to generate delayed version of the ENABLE signal where multiple ENABLE signals is required due to the configuration of the print head, for instance, as shown in
As can be appreciated from reviewing TABLE 2 together with
However, as described previously above, the method in accordance with the present invention goes a step further in that the method allows variation in pulse width and/or pulse period so that a delay may be programmed between each of the ENABLE signals. In this regard, the delay between the two ENABLE signals can be different for each graytone level in an G graytone level printing system as shown in FIG. 11. In the manner described above relative to
As can be seen by comparing the two ENABLE signals in
As can be seen from the above tables and
While various embodiments in accordance with the present invention have been shown and described, it is understood that the invention is not limited thereto. The present invention may be changed, modified and further applied by those skilled in the art. Therefore, this invention is not limited to the detail shown and described previously, but also includes all such changes and modifications.
| Number | Name | Date | Kind |
|---|---|---|---|
| 4621271 | Brownstein | Nov 1986 | A |
| 4951152 | Suzuki et al. | Aug 1990 | A |
| 4994822 | Caine | Feb 1991 | A |
| 5321427 | Agar et al. | Jun 1994 | A |
| 6079821 | Chwalek et al. | Jun 2000 | A |
| 6254225 | Chwalek et al. | Jul 2001 | B1 |
| 6331039 | Iwasaki et al. | Dec 2001 | B1 |
| Number | Date | Country | |
|---|---|---|---|
| 20030193537 A1 | Oct 2003 | US |
