The present invention relates to a method for maintenance of at least one print head of an inkjet printer, the at least one print head comprising an inlet to an ink chamber leading to a plurality of ink nozzles positioned in a nozzle surface and suitable for jetting ink, the inkjet printer comprising at least one air pressure supply unit, wherein the method comprises the step of
Marking material is meant to be an ink, for example an UV curable ink.
Image receiving medium is meant to be paper, plastic, metal, wood, transparent material, glass, cardboard, label stock, coated paper, textile or any other printable medium.
With a positive air pressure is meant an air pressure which is above ambient pressure. With a vacuum air pressure is meant an air pressure which is below ambient pressure. Hereinafter an amount of a particular air pressure is given as a difference between the particular air pressure and the ambient pressure. In other words, the air pressure is expressed as an air pressure relative to the ambient pressure.
A contact pressure may also be referred to as a mechanical pressure.
During printing the nozzle surface (or plate) may become clogged with ink residue which has to be removed in order to keep the plurality of nozzles in a good condition. The nozzle surface may contain the endings of nozzles. The ink residue may contain pigment particles. Therefore the nozzle surface (or plate) is maintained in a good health by tissue wiping. By good health is meant to prevent print artifacts such as side shooters, jet angle errors, clogging nozzles, etc. A tissue—woven or non-woven—is comprised in a cassette. The cassette may be replaced regularly, may be recyclable or may be disposable. The tissue contact the nozzle surface and also the environment of the nozzles. Spitting in the tissue is allowed by spanning the tissue horizontally below the at least one print head. Instead of only replacing the tissue the full cassette can be a consumable and replaced by the customer, to achieve a hassle free concept with safe handling of ink. The cassette can be disposed of as a whole, or recycled by replacing the used tissue by a fresh tissue (asset recovery). Spitting may be executed on several locations like above a waste tray, in the image itself e.g. by means of a blue noise bitmap.
The printer comprises:
The tissue wipe maintenance unit comprises:
The basis of the print head maintenance tissue wiper is to keep the nozzle surface (or plate) free from ink residues. The at least one print head may count a plurality of nozzles with a diameter of approximately 22.5 to 30 μm and may generate a droplet volume of approximately 6 to 10 picoliter. Within the tissue wipe concept different process flows have been defined to ensure a clean and dry nozzle surface (or plate).
These process flows are initiated by maintenance strategies. Inline or off-line print quality measurements are used as input parameters within maintenance strategies.
The following maintenance actions are known:
An antiwetting coating may be applied to the at least one print head which is a known methodology to improve jet stability and cleanliness of the nozzle surface (or plate) in time. After a certain print time period the nozzle surface (or plate) will get dirty resulting in decreasing jet stability. An effective methodology to clean the at least one print head is by use of a tissue wipe. However, the abrasiveness of the tissue wipe process towards the antiwetting coating may result in a deterioration of antiwetting behavior of the at least one print head. The most relevant contributor to the wear of the antiwetting coating are pigment particles between the tissue and the at least one print head. A solution needs to be found to allow an effective cleaning of the print head nozzle surface (or plate).
It has been confirmed that the main failure mechanism is abrasion by pigments present in the wiping nip (i.e.; contact between the tissue and the nozzle surface), probably accompanied by a small chemical reaction component.
If present, the anti-wetting coating may deteriorate quickly by abrasion by the pigment in the nip of the roller with the nozzle surface (or plate) when no countermeasures are taken. Pigment particles in the nozzle can either come from ink on the nozzle surface (or plate) (purged ink and satellite/mist contamination) or from the nozzles (sucked out by the tissue). Pigment particles are present all over the ink. Also the ink on the nozzle surface contains pigment particles which is already a potential problem to solve. By drying in of ink on the nozzle surface or in the nozzles a risk for a larger concentration of pigment particles in the nip is larger and therefore also a risk for damage. With sufficient contact pressure on the roller, ink on the nozzle surface (or plate) can be prevented from entering the nip. Hence, the damaging pigment mainly originates from the nozzles, thought to be drawn out by a suction mechanism of the tissue.
All methods available so far are not sufficient for an adequate print head cleaning without damaging the nozzle surface (or plate) by pigment particles of the ink.
It is therefore an object of the present invention to provide a method which performs an adequate print head cleaning.
It is another object of the present invention to provide an ink jet printer suitable for performing such a method.
The object is achieved in a method according to the invention, wherein the method comprises a purging step as described here-above and further comprises the step of performing a first wipe over the nozzle surface with a first contact pressure of close to 0 kPa such that the first wipe barely touches the nozzle surface, with the wet tissue comprising a wetting liquid and with a vacuum pressure provided by the at least one air pressure supply unit.
The first wipe over the nozzle surface is performed with the first contact pressure of close to 0 kPa, preferably at most 0.5 kPa.
Hereinafter the first wipe may also be referred to as the soft wipe.
The soft wipe performs two actions: it removes easily removable ink from the nozzle surface (or plate), and it pushes wetting liquid into the nozzles. The soft wipe removes all easily removable ink (including pigment particles) that can be removed with low force. Because low force is used, the risk of damaging the nozzle surface by the soft wipe is deemed low. If an antiwetting coating is provided on the nozzle surface (or plate), the soft wipe will mitigate the damage to the nozzle surface and the antiwetting coating which prolongs the lifetime of the at least one print head.
According to an embodiment the method comprises the step of d) spitting out the wetting liquid residing in the plurality of ink nozzles after the second wipe before commencing printing. Spitting means that the print head issues an actuation pulse that forces the wetting liquid in the ink nozzle to be spit out. Spitting is the act of jetting inkjet drops not for printing an image but as a part of getting or maintaining the nozzles in a good operational condition, e.g. removal of contaminations/refreshing the ink in the nozzles and removal of wetting liquid which has been sucked into the nozzles. Spitting can be performed during printing, for example at the position where the carriage with print heads reverses direction or in the print in positions where the spitted drops are not visible. In the present invention, spitting is executed after the wipes because wetting liquid is sucked into the nozzles, otherwise the first drops in the print will have a deviating color or no color at all. Spitting is the same as jetting, although slightly different settings (e.g. a different waveform of the actuation pulse) may be used to get optimal performance, for example larger drops without satellites which could contaminate the environment.
According to an embodiment the method comprises the step of c) performing a second wipe after the first wipe, the second wipe with the wet tissue comprising a wetting liquid, with a second contact pressure being higher than the first contact pressure in a range from 40 to 100 kPa and with vacuum pressure provided by means of the at least one air pressure supply unit. The purpose of the second wipe is to remove most of the remaining, preferably all ink from the nozzle surface during the second wipe. After the second wipe the nozzle surface is almost dry. Hereinafter the second wipe may also be referred to as the hard wipe.
According to an embodiment the step of performing the first wipe comprises the step of positioning the wet tissue near the nozzle surface (or plate) so that it barely touches the nozzle surface (or plate).
The step of performing the first wipe may comprise the step of pushing side rollers against bars of the nozzle surface (or plate). The side rollers may be guidance rollers which take care of a fixed distance between the wipe roller and the nozzle surface.
The step of performing the second wipe may comprise the step of applying the second contact pressure by means of springs which load bias a roller which presses the tissue to the nozzle surface (or plate) in order to ensure a constant contact pressure.
The step of performing the first wipe comprises a removal of easily removable ink residue including pigment particles residing on the nozzle surface and in the plurality of ink nozzles and a push of the wetting liquid into the plurality of nozzles. The first wipe takes care that the second wipe does not damage the nozzle surface or at least mitigates the damage to the nozzle surface.
The step of performing the second wipe comprises a removal of wetting liquid from the plurality of nozzle surface during the second wipe. The second wipe takes care of the real cleaning of the nozzle surface, also the more stuck ink. After the second wipe there is still wetting liquid in the nozzles.
The method according to the present invention comprises at least one step related to a provision of air pressure which is provided by the at least one air pressure support unit. For all those steps only one air pressure support unit maybe implemented in the printer according to the present invention. However, in case more than one air pressure support units are implemented in the printer according to the present invention, different steps related to the provision of air pressure may be provided by different air pressure support units of the printer.
The present invention further relates to a digital inkjet printer for printing images on an image receiving medium on a printing surface, the digital inkjet printer comprising a print controller, at least one print head with a nozzle surface (or plate) with ink nozzles for ejecting marking material on the image receiving medium, a wiper for cleaning the nozzle surface (or plate) with the ink nozzles and a maintenance tray for receiving marking material spit from at least part of the ink nozzles, wherein the print controller is configured to control the steps of the method according to the invention.
The present invention further relates to a software product comprising program code on a machine-readable medium, which program code, when loaded into a print controller of a digital inkjet printer for printing images on an image receiving medium on a printing surface and having at least one print head, causes the print controller to control the at least one print head in accordance with a method according to the invention, wherein the at least one print head comprises a nozzle surface (or plate) with ink nozzles for ejecting marking material on the image receiving medium, a wiper for cleaning the nozzle surface (or plate) with the ink nozzles and a maintenance tray for receiving marking material spit from at least part of the ink nozzles.
These and further features and advantages of the present invention are explained hereinafter with reference to the accompanying drawings showing non-limiting embodiments and wherein:
In the drawings, same reference numerals refer to same elements.
A purge wipe may be performed on more than one print head 21 (See
An ink purge is preventively needed to refresh ink 330 in the nozzle channels (prevent ink sedimentation and evaporation), and correctively needed to remove air or “debris” out of the nozzle channels (recover failing nozzles). The ink properties are determining the purge strategy, for example the purge volume. Ink residue 330 and wetting liquid residue 340—if any—are purged out of the nozzles 320.
An ink purge is generated by the air pressure supply unit (not shown) and will be collected in the waste bin via the purge tray unit 27. Purging in the tissue is not preferred as this limits the purge volume and due to ink migration throughout the tissue we have to feed forward the tissue each purge/wipe to create fresh tissue to wipe with, the latter consumes unwanted tissue. Before the first wipe a pressure pulse is performed by the air pressure supply unit to create the ink purge.
After the purge ink 330 is remaining on the lower surface of the nozzle surface (or plate) 320. To continue printing the nozzle surface (or plate) 320 needs to be dry and clean. To achieve this target the nozzle surface (or plate) needs to be wiped.
The pressure pulse for purging may be for example in a range of 200 to 400 mbar during a range of 200 to 2000 milliseconds. Such a pressure pulse pushes out ink as well as the wetting liquid from a previous wipe.
The part of the tissue 350 on the left side of the roller 390 contains the wetting liquid 370. Ink residue is removed from the lower surface of the nozzle surface (or plate) 310 and adheres to the tissue 350. The part of the tissue 350 on the right side of the roller 390 contains the ink residue 380.
The vacuum pressure during the first wipe is approximately 30 mbar and is used to prevent ink leakage from the nozzles 320 but mainly to soak the wetting liquid 370 in the nozzles 320.
The tissue speed is held constant at approximately 30 mm/s and the wipe speed is approximately 20 mm/s. The wetting liquid 370 is pumped into the tissue via a wetting tube (not shown) at a predefined pumping speed which makes the tissue “fairly wet”, with the roller 390 easily shining through. The roller 390 may be a 32 mm toothed roller with a hardness of approximately 45 ShA.
The vacuum pressure during the second wipe is approximately 8 mbar and is used to prevent ink leakage from the nozzles 320 and also to soak the wetting liquid 370 in the nozzles 320.
During the first wipe and the second wipe the vacuum pressure may be the same and may typically be higher than during printing. During printing the vacuum pressure is typically 10 mbar.
The second contact pressure may be applied by means of springs in order to ensure a constant contact pressure. For example, the second wipe may be applied by two springs with 8.5 N, at an impression of the roller 390 of 2.0 mm. The springs are already at a pre-tension in order to ensure a constant contact force and to be less sensitive to the impression.
In case the nozzles 320 are not continuously used the state of the nozzles are worsening over time due to ink evaporation. Periodically spitting has been developed to overcome this problem. By frequently spitting a number of drops in standby we keep the ink in the nozzle 320 fresh and ready to print. The number of spit drops can be fixed or preferred, be determined based on measuring the ink viscosity in the nozzle. The spitting is enabled by actuation, e.g. by applying an electric pulse to a piezo- or thermo-electric print head mechanism. By spitting out the wetting liquid 370 the nozzles 320 are again filled with fresh ink before printing starts.
Spitting in standby is for all printheads which need to be ready to print. Spitting is performed in a dedicated area. To limit engine pollution print head spit settings need to be optimized to reduce mist as much as possible. In order to prevent mist distribution over the engine a distance between the print head and spitting surface is minimized.
The rollers 44, 45 make contact with the bars 42 (matrix plate in which the print head 41 is mounted with high accuracy) on the side, resulting in a consistent position, chosen such that the tissue/nip roller 43 barely touches the surface of the chips 46. Image 47 gives a 3D impression of the implementation.
An implementation of both the first and the second wipe in one system could be to put the two rollers 43 (
The method starts in a start point A which leads to a first step S1.
In the first step S1 the plurality of ink nozzles is purged at least once.
In the second step S2 the soft wipe is performed over the nozzle surface (or plate) with a first contact pressure close to zero but preferably of less than 0.5 kPa such that the first wipe barely touches the nozzle surface (or plate), with a wet tissue comprising a wetting liquid, with vacuum pressure provided by the air pressure supply unit.
The method ends in an end point B.
The method starts in a start point A which leads to a first step T1 which equals the first step S1 in
The second step T2 is followed by a third step T3.
In the third step T3 the wetting liquid residing in the plurality of ink nozzles after the second wipe is spit out before commencing printing.
The method ends in an end point C.
The method starts in a start point A which leads to a first step U1 which equals the first step S1 in
The second step U2 is followed by a third step U3.
In the third step U3 a hard wipe is performed after the first wipe. The hard wipe is a second wipe with the wet tissue comprising a wetting liquid, with a second contact pressure being higher than the first contact pressure in a range from 40 to 100 kPa and with a vacuum pressure provided by the air pressure supply unit.
The method ends in an end point D.
The method starts in a start point A which leads to a first step V1 which equals the first step S1 in
The third step V3 is followed by a fourth step V4.
In the fourth step V4 the wetting liquid residing in the plurality of ink nozzles after the second wipe is spit out before commencing printing.
The method ends in an end point E.
Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually and appropriately detailed structure. In particular, features presented and described in separate dependent claims may be applied in combination and any combination of such claims are herewith disclosed. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. The terms “a” or “an”, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term coupled, as used herein, is defined as connected, although not necessarily directly.
Number | Date | Country | Kind |
---|---|---|---|
23178975.1 | Jun 2023 | EP | regional |