1. Field of the Disclosure
The present disclosure relates generally to inkjet printing systems and more particularly to systems and method for cleaning inkjet cartridges used in such systems.
2. Background of the Invention
High-speed printing systems typically include one or more imaging units. Each imaging unit has one or more inkjet cartridges and a controller controls each inkjet cartridge to eject a fluid (such as ink or other composition) onto a receiving surface. Each inkjet cartridge includes a nozzle plate that includes a plurality of orifices (nozzles) through which ink from inside the inkjet cartridge may be controllably ejected.
An inkjet cartridge typically includes a fluid chamber and one or more nozzles. Pressure inside of the fluid chamber is increased relative to ambient air pressure to force a drop of fluid through the nozzle(s). Some inkjet cartridges use a piezoelectric element that deforms a wall of the fluid chamber to reduce the volume thereof and thereby increase the pressure within the fluid chamber. Alternately, a heating element may be used to vaporize some of the fluid (or a constituent of the fluid such as a fluid carrier or a solvent) in the fluid chamber to form a bubble therein, which increases the pressure inside the fluid chamber. A controller controls the current that is passed through the piezoelectric element to control the deformation thereof or to control the current through the heating element in turn to control the temperature thereof so that drops are formed when needed. Other types of inkjet technologies known in the art may be used in the printing systems described herein.
In a printing system, an inkjet cartridge is secured to a carrier and disposed such that the nozzles of the inkjet cartridge are directed toward the receiving surface. The carrier may be manufactured from steel or other alloys that can be milled to a high precision. More than one inkjet cartridge may be secured to a carrier in this fashion in a one or two-dimensional array.
Dried ink, dust, paper fibers, and other debris can collect on a nozzle plate or in a nozzle of an inkjet cartridge and prevent proper ejection of ink from the nozzles thereof. The controller of a printing system can undertake periodic cleaning cycles during which ink is purged from the nozzle to release any debris in or near such nozzle. The purged ink and/or debris must be removed from the nozzle plate in the vicinity of the nozzles so that such purged ink and/or debris does not collect thereon and dry to create further debris that will later interfere with ejection of ink from nozzles of the cartridge.
According to one aspect of the present invention, a printing system includes a carrier, a wiping unit, a wiper transport, and a wiper wash unit. A plurality of inkjet cartridges is disposed on the carrier and the wiping unit includes a plurality of wiper blades. The wiper transport effects relative movement between the carrier and the wiping unit such that the plurality of wiper blades cleans the plurality of inkjet cartridges and a wiper wash unit actuator causes the wiper wash unit to clean the plurality of wipers.
According to another aspect of the present invention, a method of cleaning a plurality of inkjet cartridges disposed on a carrier includes the step of providing a wiping unit, wherein the wiping unit includes a plurality of wipers. The method includes the further steps of effecting relative movement between the wiping unit and the carrier such that the wipers clean the plurality of inkjet cartridges and actuating a wiper wash unit to clean the wiper blades.
According to a further aspect of the present invention, a printing system includes a carrier, a bay, and a transport system. A plurality of inkjet cartridges is disposed on the carrier and the transport system effects relative movement between the carrier and the bay. The printing system also includes a sealing member for the bay. When the carrier is positioned over the bay, the sealing member substantially protects the a surface of the carrier from the environment outside the bay.
According to a still further aspect of the present invention, a method of storing inkjet cartridges disposed on a carrier includes the steps of effecting relative movement between the carrier and a bay, and forming a seal between the carrier and the bay. The seal substantially protects the carrier from the environment outside the bay.
In some printing systems, the inkjet cartridge 110 is secured to a mount (not shown) and the mount is thereafter secured to the carrier 106. U.S. Provisional Patent Application Ser. No. 61/535,150 entitled “Apparatus and Method for Disposing an Inkjet Cartridge in a Mount” discloses one such mount. The entire contents of such application are also incorporated herein by reference.
A controller 114 controls the operation of the print unit 100 and the cleaning unit 102 as is described further hereinafter.
A web of paper (not shown) is transported through a space 116 between the outer surface 112 of the drum 104 and the carrier 106 such that the nozzles of the inkjet cartridges 110 disposed in the carrier 106 face toward the web of paper. In one embodiment, rotation of the drum 104 transports the paper past the nozzles of the inkjet cartridges 110.
Periodically, the controller 114 initiates a cleaning cycle and moves the carrier 106 into a cleaning position shown in
In some embodiments, the controller 114 initiates a cleaning cycle after the print unit 100 has been operated for a predetermined period of time. In other embodiments, the controller 114 detects a paper splice or a roll change and initiates the cleaning cycle. In some cases, the controller stops the transport of the paper, for example, by stopping rotation of the drum 104. In other cases, the transport of the paper is uninterrupted while the cleaning cycle is undertaken, for example, if the cleaning cycle coincides with a roll change or a paper splice. It should be apparent that the cleaning cycle could be undertaken at any time while the cartridges 110 are not being used to print and with or without stopping the transport of the web.
The cleaning unit 102 also includes a cleaning bay 306. In one embodiment the cleaning bay 306 has a bottom surface 308 that is angled downward toward a catcher pan 310 disposed in the underside of the cleaning unit 102. The bottom surface 308 is configured such that liquid deposited thereon flows into the catcher pan 310.
The cleaning unit 102 further includes a wiper wash unit 312. The wiper wash unit 312 comprises a plurality spray units, described hereinbelow, supplied by fluid distribution units 314 (for example, a t-joint for directing fluid).The distribution units 314 extend outwardly from a top surface 313 of the wiper wash unit 312. Each fluid distribution unit 314 may supply one or more spray units. The fluid distribution units 314a through 314f are coupled to one another using, for example, fluid lines (shown for clarity in
The wiper wash unit 312 includes valves 327a, 327b, and 327c that may be controlled by the controller 114 and an input portion of each valve 327 may be connected to a source of pressurized fluid such as water, a cleaning solution, a gas, air, or a combination thereof. In one embodiment, the valves 327 are electrically controllable solenoid valves. The output ports of one or more of the valves 327 may connected to a common fluid line and the common fluid line connected to the input port 316a of the distribution unit 314a.
As is described further below, in one embodiment, an aqueous cleaning solution is provided to the input port 316a for a first period of time by opening the valve 327 connected to the source of such solution. Thereafter, the valve 327a connected to the source of cleaning solution is closed and air is provided for a second period of time by opening the valve 327c connected to such air. The controller 114 operates the valves 327 to provide cleaning solution and air as required. Other combinations of fluids over various periods of time may be supplied to the input port 316a and thereby to the distribution units 314a through 314f and the spray units associated therewith.
In one embodiment, the spray units 332 are connected by fluid lines (not shown) to the distribution units 314a through 314e. Referring to
During a cleaning cycle, the controller 114 actuates motor drives (not shown) in the press unit 100 to position the carrier 106 over the cleaning bay 306. Thereafter, the controller 114 causes the inkjet cartridges 110 to eject ink from the nozzles thereof for a predetermined period of time as described above. Such ejected ink is deposited onto the bottom surface 308 of the cleaning bay 306 and transported by gravity to the catcher pan 310.
In one embodiment, the controller 114 actuates one or more motors in the cleaning unit 102 associated with the wiper unit 302 to move the wiper unit 302 in the direction A seen in
In some embodiments, after wipers 304 have been washed with the cleaning fluid, the controller 114 actuates another of the valves 327 to supply a drying fluid (such as air) to the input nozzle 316a. Again, the drying fluid is supplied with sufficient pressure so that such fluid is distributed to each of the distribution units 314 and is forcefully ejected from each spray unit 332. In a preferred embodiment, the drying fluid is air and is supplied to the input port 316a at a pressure of between approximately 60 and 90 PSI. In addition, the drying fluid is supplied for a predetermined amount of time to dry the wipers 304. In other embodiments, the wipers 304 are allowed to air dry.
After the wipers 304 have been cleaned as described hereinabove, the controller 114 actuates the motor of the wiper unit 302 to cause the wiper unit 302 to move the direction A′ until the wiper unit 302 is positioned at the left most position of the cleaning unit (as shown in
In some embodiments, the wiper unit 302 is parked under the wiper wash unit 312 when not in use. In such embodiments, the controller 114 actuates motor of the wiper unit 302 to move the wiper unit 302 in the direction A′ until the wipers 304 are aligned with a set of inkjet cartridges 110 nearest the wiper wash unit 312. The controller 114 actuates the pneumatic lifter with each wiper 304 so that the wiper 304 contacts the nozzle plate of each inkjet cartridge 110 in such set of inkjet cartridges 110. Thereafter, the controller 114 actuates the motor of the wiper unit 302 to move the wiper unit 302 in the direction A′ a distance identical to the width of the nozzle plate of an inkjet cartridge 110, thereby wiping the surface of such nozzle plate with the wiper 304. The controller 114 thereafter releases the pneumatic lifter associated with each wiper 304 to return such wiper to a resting position. The controller 114 then actuates the motor of the wiper unit 302 to move the wiper unit 302 in the direction A′ to the next set of cartridges 110 and repeats the wiping process. After all of the cartridges 110 have been wiped in this fashion, the controller actuates the motor of the wiper unit 302 to move the wiper unit 302 in the direction A to be positioned under the wiper wash unit 312. Thereafter, the wiper wash unit 312 cleans the wipers 304 of the wiper unit 302 as described above.
In one embodiment, the controller 114 transports the wiper unit 302 into position under the wiper wash unit 312 and directs a wiper cleaning cycle described above after each set of inkjet cartridges 110 are wiped. It should be apparent that such wiper cleaning cycle may be undertaken periodically during the cleaning of the inkjet cartridges 110 secured to the carrier 106.
In one embodiment, one or more spray unit(s) (not shown) may be disposed in the cleaning unit so that fluid ejected therefrom may clean the bottom and/or side surfaces of the cleaning Fluid lines to one or more of the valve(s) 327 connect such spray unit(s) and the controller 114 opens such valve periodically to clean such bottom and/or side surfaces.
In one embodiment, the piston 518 may be threaded and a screw (not shown) may be provided in the interior portion of the wiper 304. An operator may turn the piston 518 and, therefore, the wiper blade 506 to adjust the distance between the piston 518 and the top surface 522 of the mounting plate 512 to be adjusted. Each turn of the piston 518 is associated with a predetermined change in the distance between such piston 519 and the top surface 522. In one embodiment the pitch of the thread is 1/32 of one inch and each turn adjusts the distance accordingly. Such adjustment allows and operator to precisely position the wiper 304 with respect to a nozzle plate that is cleaned by such wiper 304.
The cleaning unit 102 may be used to provide a controlled environment in which to park the carrier 106 and the inkjet cartridges 110 mounted therein when such inkjet cartridges 110 are not being operated to print.
Because, with the cover 700 in a closed position, the carrier 106 and the cartridges 110 are in a sealed environment, the controller 114 may adjust the ambient pressure in such environment as necessary. For example, the controller 114 may increase the ambient pressure introducing air from one or more of the spray unit(s) 332 or decrease the ambient pressure by actuating a vacuum (not shown). The pressure may be increased, for example, to force ink into the body of the inkjet cartridge 110 and away from the nozzles thereof. Alternately, the pressured may be decreased to cause ink to weep from the nozzles of the inkjet cartridge 110.
When the carrier 106 and the inkjet cartridges 110 are in the parked position, the controller may adjust the pressure with which ink is supplied to the cartridges 110, for example, to cause the inkjet cartridges 110 to weep ink from nozzles thereof periodically. It should also be apparent that the controller 114 may exercise the heads (e.g., by purging ink) periodically while the carrier is in the parked position to ensure that the cartridges 110 are maintained in a print-ready state.
Referring once again to
In some embodiments the cover 700 is closed during a cleaning cycle or a portion thereof. In other embodiment the cover 700 may be kept open or partially closed during a cleaning cycle or portion thereof. Further, it should be apparent that when the carrier 106 is moved into the cleaning unit 102 or when the cleaning unit 102 is moved under the carrier 106, the cover 700 may be closed during transport, and then opened while the carrier 106 is positioned into the cleaning bay 306.
To initiate the cleaning process, the cover 700 is moved to the open position and the controller 114 actuates the motor 1010. Actuation of the motor 1010 rotates the lifting screw 1008 and thereby causes the lifting member 1006 to movement upward along a direction D. The upward movement of the lifting member 1006 causes the plates 1002,1004 and the carrier 106 secured to such plates to also move along the direction D and away from the drum 104. Thereafter the controller 114 actuates the motor 1014 to rotate the drive screw and transports the cleaning unit 102 in the direction E until the cleaning unit is 102 is positioned under the carrier 106. Thereafter, the controller 114 actuates the motor 1010 to move the carrier downward in a direction opposite to the direction D until the carrier 106 rests over the cleaning bay 306 of the cleaning unit 102.
A wall member 1020 is secured to a sidewall 1022 of the cleaning unit 102. The wall member 1020 includes an outer edge 1024 that conforms to the side edge 1026 of the carrier 106. A similar wall member (not shown) is secured to a sidewall (not shown) opposite the sidewall 1022 of the cleaning unit 102. A continuous sealing member 1028 is disposed along the outer edges 1018 and 1024 of the wall members 1016 and 1020, respectively, and the outer edges of the wall members opposite the wall members 1016 and 1020. In one embodiment the continuous sealing member 1028 is a compressible hollow rubber tube. It should be apparent that other materials such as silicone, plastic, foam, or other compressible materials may comprise the sealing member 1028.
During the cleaning process and for storage, the controller actuates the motor along the direction opposite to the direct D until the carrier 106 compresses the sealing members 1028 thereby sealing nozzle plates of the inkjet cartridges disposed in the carrier 106 to protect the volume of space between the bottom surface the carrier 106 and the cleaning bay 306 of the cleaning unit 102 from the environment outside the cleaning unit 012. The humidity, pressure, and temperature in such volume of space may be controlled as described above.
In one embodiment, the wall members 1016 and 1020, and wall members opposite thereto are secured to carrier 106. In such embodiments, such wall members are not secured to the sidewalls of the cleaning unit 102. Rather, the sealing member 102 is secured to the top edges of the sidewalls 1017 and 1022 and sidewalls opposite thereto. During cleaning and storage, the bottom edges of the wall members 1016 and 1020 are urged downward to form a seal with the sealing member 1028. The sealing member 102 may be secured to the bottom surfaces of the wall member 1016 and 1020, and wall members opposite thereto, and not the top edges of the sidewalls 1017 and 1022, and sidewalls opposite thereto.
Numerous modifications to the present embodiments will be apparent to those skilled in the art in view of the foregoing description. Accordingly, this description is to be construed as illustrative only and is presented for the purpose of enabling those skilled in the art to make and use the embodiments and to teach the best mode of carrying out same.
The present application claims the benefit of Moscato et al., U.S. Provisional Patent Application No. 61/685,002, filed on Mar. 9, 2012, and entitled “System and Method of Cleaning Inkjet Cartridges.” The entire contents of such application are incorporated herein by reference.
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