The present invention relates to a method and apparatus for reducing nozzle failure in printheads that have been stored or otherwise unused for extended periods.
Most inkjet printers dispense colorants or inks that are comprised of a dye and/or a pigment that is either dissolved or suspended in a volatile solvent. When the print head of the printer deposits the colorants on a recording media such as paper or film, the solvents in the colorants quickly evaporate, leaving the dyes and/or pigments behind on the recording media.
During the manufacturing process printheads for inkjet printers must be tested. Accordingly, it is customary to provide an inkjet printhead with a dye and/or pigment based colorant that will be dispensed from the printhead as a test to ensure that the printhead functions properly. It may also be necessary to include a colorant with a printhead so that a printer in which the printhead is installed may be tested.
However, where colorants are allowed to remain in a printhead for extended periods of time, it is often the case that the volatile solvents that make up the colorants will at least partially evaporate, leaving within the nozzles of the print head a residue of particles or a precipitate.
a is a schematic view of a typical nozzle 12 in an inkjet printhead 10. As will be readily understood by those skilled in the art, a printhead 10 typically includes multiple nozzles 12, each of which is connected to a reservoir (not shown) by a conduit 14. Generally, a single conduit 14 will supply colorant 13 to multiple nozzles 12. In a thermal inkjet printhead, a small resistor 16 will be provided adjacent to the opening of the nozzle 12. The resistor 16 ejects colorant 13 from the nozzle 12 by rapidly raising the temperature of the colorant 13 so as to cause the solvent thereof to boil. The rapid expansion of the boiling solvent ejects a droplet (not shown) of colorant 13 from the opening of the nozzle 12 in a known manner. Other types of inkjet printheads may utilize a piezoelectric element in lieu of the resistor 16.
The printhead 10 illustrated in
In order to retard the evaporation of the solvents from a colorant, it is common to either cover the nozzles of a printhead with tape or else to ensure that the printhead is otherwise covered with a cap. While such methods do slow the evaporation of solvents from the colorant, simply covering a nozzle is not sufficient to prevent the formation of accretions in a nozzle where the printhead is placed in storage for an extended period of time. Accordingly, there is a recognized need for a method and/or and apparatus that will prevent the formation of accretions in the nozzles of the printhead, particularly where the printhead must be stored for extended periods of time either before it is used or between uses.
a-1c are a schematic time-lapse depiction of a prior art printhead wherein solvents in a colorant evaporate to form an accretion in a nozzle;
In the following detailed description, reference is made to the accompanying drawings that form a part hereof, and in which is shown, by way of illustration, exemplary embodiments in which the invention may be practiced. In the drawings, like numerals describe substantially similar components throughout the several views. These embodiments are described in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments may be utilized and structural, logical, and electrical changes may be made without departing from the scope of the present invention. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the present invention is defined only by the appended claims and equivalents thereof.
Colorants are supplied to the nozzle 22 through a conduit 24. The conduit 24 is fluidically connected to a reservoir (not shown) that provides a continuous supply of a colorant 26. While the exemplary methods and apparatuses herein may apply to any printhead or printing mechanism that utilizes a colorant 26 that comprises a volatile solvent, this description focuses on an exemplary thermal inkjet printhead embodiment. A resistor 28 is electrically connected to a controller via conductor 30. The controller (not shown) applies a current to the resistor 28, which boils the solvent in the colorant 26 immediately adjacent to the resistor 28. The boiling of the solvents creates a vapor bubble whose expansion ejects a droplet of the colorant 26 from the nozzle 22 so as to form an image on a recording media (not shown).
Because it may be necessary to test the printhead 20 after its manufacture, or test a printer (not shown) in which the printhead 20 has been installed, a first, dilute colorant 26a is inserted into the printhead 20 so as to substantially fill the nozzle 22. Note that the first colorant 26a must fill that portion of the nozzle 22 immediately adjacent to its opening. The first colorant 26a may also fill some portion of or the entire conduit 24 as well. Preferably, a second, more concentrated colorant 26b is placed in a reservoir 32 (see
It has been found that the number of malfunctioning nozzles 22 present in a printhead 20 is directly related to both the concentration of the colorant 26 and to the length of time that the printhead 20 is in storage. Accordingly, the insertion of a first, more dilute colorant 26a directly into the nozzle 22 adjacent the opening thereof results in fewer malfunctioning nozzles 22 over a given period of time. Thus, as the solvents in the first colorant 26a will likely continue to evaporate, the lower concentration of dyes and/or pigments in the first colorant 26a results in the slower growth of accretions in the opening of the nozzle 22.
In certain embodiments, the first colorant 26a is simply a more dilute version of the more concentrated second colorant 26b. Once the printhead 20 has been manufactured, the first colorant 26a is inserted through the conduit 24 in into the nozzle 22. The second colorant 26b is then injected into the reservoir 32. While the concentration of dyes and/or pigments in the first colorant 26a is lower than that of the second colorant 26b, the concentration is sufficient to allow the printhead 20 to be tested, as is commonly the practice, and yet yields fewer malfunctioning nozzles 22 after storage of the printhead 20 for a given period of time.
In certain other embodiments, the second colorant 26b is inserted into the printhead 20 at least part way into the conduit 24 but possibly also partly into the nozzle 22, keeping in mind that the first colorant 26a is to occupy the majority of the nozzle 22, and possibly all of the nozzle 22. Note that the dimensions of the conduit 24 in the nozzle 22 are such that the colorants 26a and 26b will not be significantly mixed together. Accordingly, it is possible for colorants 26a and 26b, differing only in their concentration is of dyes and/or pigments, to coexist side-by-side for extended periods of time without any significant mixing.
In some instances it may be preferable to utilized dissimilar colorants 26a and 26b. As used herein, the term “dissimilar” should be taken to include colorants 26 comprising different combinations and concentrations of solvents, and coloring agents such as dyes and/or pigments. By way of example only, in some instances it may be desirable to utilize a colorant 26a that has a different hue, or for that matter a completely different color, than the colorant 26b. To further prevent mixing of the colorants 26a, 26b it may be desirable to select solvents for the respective colorants that are dissimilar or even immiscible with one another. Alternatively, it may be desirable to select a solvent or mixture of solvents for use in the colorant 26a that have a relatively low volatility.
During normal operation, pump 34 is actuated to move colorant from the reservoir 32 through the line 33 into the conduit 24. The valve 36 may be operated to selectively open and close the line 33, thereby permitting or preventing, as the case may be, the flow of colorant from the reservoir 32 into the conduit 24. The colorant 26 flows through the conduit 20 either due to the force of gravity or as the pump 34 has pressurized the colorant 26 in the conduit 24.
As part of the manufacturing process, or as part of a “mothballing” procedure, the apparatus illustrated in
In certain exemplary embodiments, multiple reservoirs 32 may be used. In the illustrated embodiment, the printhead 20 is prepared for printing an image on recording media by actuating the colorant delivery system 31 to withdraw the first colorant 26a from the printhead 20 and into a first reservoir 32. Once the first colorant 26a has been removed from the printhead 20, the reservoir 32 containing the first colorant 26a is uncoupled from the colorant delivery system 31 and a second reservoir 32, this one having the second colorant 26b contained therein, is coupled to the colorant delivery system 31. The colorant delivery system 31 is then actuated to provide the second colorant 26b to the printhead 20 for printing. The first colorant 26a may be conserved in the first reservoir 32 or may be discarded. Where it is desirable to “mothball” the printhead 20, the colorant delivery system 31 may be actuated to withdraw the second colorant 26b from the printhead 20 back into its reservoir 32 for conservation. Thereafter, the first colorant 26a may be reintroduced into the printhead 20 by coupling a reservoir 32 having the first colorant 26a contained therein to the colorant delivery system 31. The colorant delivery system 31 will then be actuated to reintroduce the first colorant 26a into the printhead 20.
The nozzles 22 of the printhead 20 may be closed as by capping or taping and as seems appropriate given the application to which the printhead 20 will be put. The printhead 20 may then be placed into storage or otherwise inactivated. Note that the printhead 20 may be detached from the line 33 and stored apart from the reservoir 32, pump 34 and valve 36, may be installed in a printer along with the reservoir 32, pump 34, and valve 36 for storage, or a combination of the reservoir 32, pump 34 and valve 36 may be stored together with the printhead 20 in an integral package. For the purposes of the present application, the term “storage” should be taken to mean the reservation of the printhead 20 at a location remote from a printer or an extended period of inactivity where the printhead 20 is installed in a printer. The second colorant 26b may be retained entirely within the reservoir 32, leaving only the first colorant 26a in the conduit 24. Alternatively, the second colorant 26b can be inserted into the conduit 24 behind and up to the first colorant 26a up to line 27 as shown in
Where the printhead 20 is currently in use but is to undergo a period of prolonged in activity, a mothballing procedure may be performed upon the printhead 20. During such a procedure, relatively concentrated colorant 26b present in the conduit 24 and nozzles 22 is either ejected or is withdrawn into the reservoir 32 by means of the pumping action of the pump 34 through line 33. Thereafter, dilute colorant 26a may be inserted into the conduit 24 through the aforementioned port so as to substantially fill the nozzles 22. In an alternate embodiment, and as it is likely that some quantity of concentrated colorants 26b may be retained with in the conduit 24 and nozzles 22, a compatible solvent not having a dye and/or pigments included therein may be inserted into the conduit 24 to be mixed with the second colorant 26b remaining in the conduit 24 by means of pulsing the pump 34 as described hereinabove. Alternatively, the pure solvents added to the conduit 24 may be drawn through the conduit 24 and expelled from the nozzles 22 by the normal operation of the nozzles 22, the nozzles 22 being operated so as to draw sufficient quantities of the pure solvents into the nozzles 22 to reduce the incidence of malfunction in the nozzles 22 when the printhead 20 is installed and/or reactivated.
Upon installation of the printhead 20 in a printer, or upon reactivation of the printhead 20 in a printer, printing of an image upon recording media may commence using the first colorant 26a. The use of a dilute mixture of the second colorant 26b as the first colorant 26a may allow the printhead 20 to begin printing in such a way as to produce images of an acceptable quality where the color, hue, and/or intensity of the first colorant 26a is near enough to satisfy the image quality requirements expected of images printed using the second colorant 26b. Alternatively, one or more test images or patterns may be printed for the express purpose of exhausting the supply of the first colorant 26a within the printhead 20 prior to the start of printing using the desired second colorant 26b.
The apparatus illustrated in
In operation, the printhead 20 is first installed in a printer or is reactivated after a period of inactivity; pump 44 is actuated to draw the first colorant 26a from the nozzle orifice plate 23 and conduit 24 of the printhead 20 and into the priming cap 42. The first colorant 26a is then deposited into the priming reservoir 46. In this embodiment, once the first colorant 26a is removed from the printhead 20 in deposited in the priming reservoir 46, it will not be reused. It is to be understood however that the first colorant 26a may be reused where so desired.
As the first colorant 26a is drawn from the printhead 20, the action of the pump 44 will simultaneously draw the second colorant 26b from the reservoir 32 into the condiut 24 and subsequently into the nozzles of the nozzle orifice plate 23. At this point, the printhead 20 is ready to begin printing an image using the second colorant 26b.
Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that any arrangement that is calculated to achieve the same purpose may be substituted for the specific embodiments shown. Many adaptations of the invention will be apparent to those of ordinary skill in the art. Accordingly, this application is intended to cover any adaptations or variations of the invention. It is manifestly intended that this invention be limited only by the following claims and equivalents thereof.