Inkjet printing technology is used to print documents in many homes and businesses. Inkjet printers typically operate by selectively dispensing tiny droplets of liquid ink onto a print medium in a pattern corresponding to the desired text and/or images.
Many inkjet printers have a printing cartridge with an incorporated printhead having orifices through which liquid ink is expelled onto the print medium. Various print cartridge configurations exist. One configuration is that of a disposable print cartridge, typically including a self-contained ink or fluid reservoir and a printhead. Once the fluid reservoir is depleted, the print cartridge is replaced with a fresh cartridge. In other configurations, permanent or semi-permanent cartridges may receive liquid ink from a replaceable supply.
In inkjet printing, it is often important to maintain a sufficiently primed supply of ink to the printhead. However, when a print cartridge is first installed, or after long periods of disuse, one or more pockets of air may be present within the ink channels of the printhead. Under such circumstances, it may be desirable to prime the printhead by establishing a flow through the ink channels and out the nozzles such that any air bubbles are flushed out of the printhead.
The accompanying drawings illustrate various embodiments of the principles described herein and are a part of the specification. The illustrated embodiments are merely examples and do not limit the scope of the claims.
Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
As mentioned above, it may be desirable to prime an inkjet printhead or other fluid dispenser by removing gaseous bubbles disposed within liquid ink channels to and in the printhead. In some cases, it may be easier to move and push larger bubbles out of the dispensing head than smaller bubbles. Thus, it may be desirable to facilitate the enlargement or aggregation of gaseous bubbles within the liquid ink channels of fluid-dispensing heads. Moreover, it may also be desirable to reduce the surface tension in gaseous bubbles within the liquid ink channels of a fluid-dispensing head to facilitate the removal of the gaseous bubbles from the orifices within the dispensing head.
To better accomplish these goals, the present specification discloses illustrative systems and methods for priming a fluid-dispensing head, such as an inkjet printhead. The systems and methods may involve heating liquid ink within the dispensing head such that gaseous bubbles present in the liquid ink increase in size and reduce in surface tension.
As used in the present specification and in the appended claims, the term “fluid-dispensing head” or “dispensing head” refers to a device within a fluid dispenser, such as an inkjet printer, having at least one orifice through which fluid or liquid, such as ink, may be selectively deposited, for example, onto a print medium, such as a sheet of paper or other print media. In some fluid dispensers, a dispensing head or printhead may be a component in a replaceable and disposable cartridge.
In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present systems and methods. It will be apparent, however, to one skilled in the art that the present systems and methods may be practiced without these specific details. Reference in the specification to “an embodiment,” “an example” or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment or example is included in at least that one embodiment, but not necessarily in other embodiments. The various instances of the phrase “in one embodiment” or similar phrases in various places in the specification are not necessarily all referring to the same embodiment.
The principles disclosed herein will now be discussed with respect to illustrative systems and methods.
Illustrative Systems
Referring now to
The computing device (110) that is controllably coupled to the servo mechanism (120) and the fluid dispenser (150), as shown in
When accessed by the computing device (110), these instructions are used to control the servo mechanism (120) to selectively position the movable carriage (140) and fluid dispenser (150). The computing device (110) may be, but is in no way limited to, a workstation, a personal computer, a laptop, a digital camera, a personal digital assistant (PDA), or any other processor-containing device.
The moveable carriage (140) of the present illustrative system (100) may support and position any number of fluid dispensers (150) configured to selectively dispense the fluid (160) used by the system, for example, ink. The moveable carriage (140) may be controlled by a computing device (110) and may be controllably moved by, for example, a shaft system, a belt system, a chain system, etc. making up the servo mechanism (120). As the moveable carriage (140) operates, the computing device (110) may inform a user of operating conditions as well as provide the user with a user interface.
In a printing application, as a desired image or text is printed on the fluid-receiving medium (170), the computing device (110) may controllably position the moveable carriage (140) and direct one or more of the fluid dispensers (150) to selectively dispense an inkjet ink at predetermined locations on the medium (170) as digitally addressed drops, thereby forming the desired image or text. The fluid dispensers (150) used by the present exemplary system (100) may be any type of fluid dispenser configured to perform the present method including, but in no way limited to, thermally actuated fluid dispensers, mechanically actuated fluid dispensers, electrostatically actuated fluid dispensers, magnetically actuated fluid dispensers, piezoelectrically actuated dispensers, continuous fluid dispensers, etc. Additionally, the present fluid-receiving medium (170) may receive fluids from other sources such as, but in no way limited to, screen printing, stamping, pressing, gravure printing, and the like.
The fluid reservoir (130) that is fluidly coupled to the fluid dispenser (150) may house and supply a fluid (160), such as an inkjet ink to the fluid dispenser. The fluid reservoir (130) may be any container configured to hermetically seal the fluid (160) prior to dispensing.
According to the present exemplary embodiment, the fluid (160) contained by the reservoir (130) may include, but is in no way limited to, pigment-based and dye-based inkjet inks. Appropriate dye-based inks include, but are in no way limited to anionic dye-based inks having water-soluble acid and direct dyes. Similarly, appropriate pigment-based inks include both black and colored pigments. Moreover, the inkjet ink compositions of the present exemplary systems and methods are typically prepared in an aqueous formulation or liquid vehicle that can include, but is in no way limited to, water, cosolvents, surfactants, buffering agents, biocides, sequestering agents, viscosity modifiers, humectants, binders, and/or other known additives.
Referring now to
The inkjet print cartridge (200) may include an ink reservoir (201) and a dispensing head (203) which may perform at least some of the functions of the fluid material reservoir (130,
A back surface of the tape (209) may include conductive traces (shown in
The aforementioned traces may be formed on the back surface of the tape (209) (opposite the surface which faces the fluid-receiving medium). To access these traces from the front surface of the tape (209), holes (vias) may be formed through the front surface of the tape (209) to expose the ends of the traces. The exposed ends of the traces may then be plated with, for example, gold to form the contact pads (211) shown on the front surface of the tape (209).
Windows (213, 215) extend through the tape (209) and are used to facilitate bonding of the other ends of the conductive traces to electrodes on a silicon substrate containing heater resistors. The windows (213, 215) are filled with an encapsulant to protect any underlying portion of the traces and substrate.
In the print cartridge (200) of the present example, the tape (209) is bent over the back edge of the print cartridge “snout” and extends approximately one half the length of a back wall (217) of the snout. This flap portion of the tape (209) may be useful for the routing of conductive traces which may be connected to the substrate electrodes through the far end window (213).
A semiconductor die (shown in
The orifices (207) and conductive traces may be of any size, number, and pattern, as suits a particular application. The orifice pattern on the tape (209) shown in
Referring now to
Portions of conductive traces (407) formed on the back of the tape (209) are also shown in
Referring now to
Electrodes (503) may also be formed on the semiconductor die (401) for connection (shown by dashed lines) to the conductive traces (407) formed on the back of the tape (209,
The barrier layer (403), which may be a layer of photoresist or some other polymer, may include vaporization chambers (507) and ink channels (509). A portion (500) of the barrier layer (403) may insulate the conductive traces (407) from the underlying semiconductor die (401.
In order to adhesively affix the top surface of the barrier layer (403) to the back surface of the tape (209,
Referring now to
Adhesive seals (601) may secure at least a portion of the cartridge walls (602) to the tape (209). The barrier layer (403) of the semiconductor die (401) may be secured to the tape (209) using the thin adhesive layer (511). Thin film resistors (607, 609) are shown within the vaporization chambers (603, 605) respectively.
Fluid from a fluid reservoir, for example, an ink reservoir (201,
In some embodiments, the fluid reservoir may contain two or more separate fluid sources, for example, each containing a different color of ink. In this alternative embodiment, the plenum (613) in
This concept can even be used to create a four color dispensing head, where a different ink reservoir feeds ink to ink channels along each of the four sides of the substrate. Thus, instead of the two-edge feed design discussed above, a four-edge design would be used, preferably using a square substrate for symmetry.
As described previously, it may be desirable for many fluid-dispensing systems and cartridges (200) with dispensing heads (203) to be substantially free of gaseous bubbles in fluid channels, such as the plenum (613) and the vaporization chambers (603, 605) for proper operation. However, gaseous bubbles may be introduced into a fluid-dispensing system under a variety of situations, for example, bubbles may occur prior to the commencement of initial fluid-dispensing operations, after long periods of. inactivity, and even during operations. For this reason, many fluid-dispensing systems, such as the cartridge (200) illustrated, rely on priming operations to remove gaseous bubbles (615) from these fluid channels. Priming operations typically force gaseous bubbles (615) out of the dispensing head (203) by pushing fluid through the orifices (207).
Fluid-dispensing systems (e.g., 100,
In the present systems and methods, the semiconductor die (401) may be heated such that the gaseous bubbles (615) grow larger during priming and may thus be rendered easier to remove from the dispensing head (203). This heating of the semiconductor die (401) may include passing an electrical current through some or all of the thin film resistors (607, 609) or other dedicated heating elements such that the semiconductor die (401) is warmed by thermal energy dissipated by the energized resistors (607, 609).
During normal fluid-dispensing operations, the thin film resistors (607, 609) may be used to heat surrounding fluid beyond a boiling point of the fluid in the vaporization chambers (603, 605) such that fluid droplets are expelled through the orifices (207) by expanding vapors from the fluid. However, in the present system for priming the dispensing head (203), the thin film resistors (607, 609) may be selectively energized such that the fluid in the general vicinity of the semiconductor die (401) is heated to a temperature such that bubbles (615) expand, but the fluid does not boil. For example, in some embodiments the semiconductor die (401) may be heated to approximately 80 degrees Celsius to facilitate priming the dispensing head (203).
It will be understood that while the present systems incorporate thermal dispensing heads (203) having thin film resistors (607, 609), the principles described herein are not limited to only thermally-actuated fluid-dispensing system. For example, priming systems described herein may be used in conjunction with piezoelectric fluid dispensers, bubble jet fluid dispensers, and other types of fluid dispensers according to specific applications. While some embodiments of fluid-dispensing systems may not require heating element(s) for printing operations, thin film resistors or other heating elements may still be provided disposed within such systems for improved priming operations as described herein.
Control circuitry may selectively activate the thin film resistors (607, 609) as needed to heat the bubbles (615) and surrounding fluid according to priming operations described herein. In some embodiments, this control circuitry may be included in the electronics of a printing system configured to house the inkjet print cartridge (200). Control signals may be received at the semiconductor die (401) in accordance with principles described previously. In other embodiments, the control circuitry may be at least partially housed within the inkjet print cartridge (200), or anywhere else, as may suit a particular application.
In some embodiments, a temperature sensor (617) may be disposed within the dispensing head (203) assembly or elsewhere in the cartridge (200) or dispensing system to measure the temperature of the fluid and/or bubbles (615). The temperature sensor (617) may be in communication with the control circuitry such that the control circuitry may selectively activate/deactivate the thin film resistors (607, 609) to heat the fluid and/or bubbles (615) to a desired temperature.
The volume of a bubble (615) is largely a function of its temperature and the amount of gas contained therein. Therefore, when the fluid in the cartridge (200) or dispensing system is heated by the semiconductor die (401), bubbles (615) within the fluid will also be warmed. This increase in temperature may cause an increase in the volume of the gas in the bubble, as heated gases tend to expand.
According to the ideal gas law, the increase in volume of a heated bubble (615) is directly proportional to the increase in absolute temperature experienced by the bubble (615). For example, according to the ideal gas law, if the absolute temperature of a bubble is increased by 15%, the volume of the bubble (615) will also increase by a corresponding percentage. Furthermore, an increase in fluid temperature also encourages outgassing by moving dissolved gases in the fluid into existing bubbles (615), thus further increasing bubble size and facilitating the removal of gases from the fluid within the cartridge (200) or other fluid-dispensing system while discouraging the formation of subsequent bubbles (615).
As fluid is flushed through the orifices (207) during priming operations, larger bubbles (615) may be easier to move with the flow of the fluid, e.g., requiring less fluid flow pressure to move, than bubbles of the same mass at a lower temperature and smaller size. This may be due, at least partially, to the larger surface area of the enlarged bubbles (615).
Moreover, a bubble (615) that is being primed out of the dispensing head (203) must overcome the pressure and surface tension at the smallest constriction in its path. As bubble pressure is directly proportional to surface tension, and the surface tension of the bubble (615) tends to decrease with increasing temperature, the bubble pressure and surface tension may decrease as the temperature of the bubble (615) increases, even though the bubble is increased in size. Thus, increasing the temperature while priming may also help to reduce the threshold pressure that must be overcome to prime the bubble (615) through the smallest constriction in its path.
In some embodiments, additional thin film resistors or other heating elements may be disposed within the print cartridge (200) or other fluid-dispensing system and the dispensing head (203) assemblies. Additional heating elements may facilitate more uniform and/or effective heating of fluid within a desired priming region.
Referring now to
Referring now to
In summary, the present systems and methods utilizing die heating for priming operations may provide numerous advantages over previous priming systems. For example, the present systems and methods may enable more effective removal of gaseous bubbles (615) from inkjet print cartridges (200) and other fluid-dispensing systems that include dispensing heads (203) by enlarging the gaseous bubbles (615). The present systems and methods may also enable removal of portion of dissolved gasses thereby reducing the likelihood of subsequent bubble formation. Additionally, warming the fluid and gaseous bubbles (615) during priming may help reduce surface tension that needs to be overcome when passing the gaseous bubbles (615) through constrictions in the dispensing heads (203).
Because of the more efficient removal of the gaseous bubbles (615), less fluid may be used during priming operations, thus conserving more fluid for actual dispensing operations. This may also decrease damage to the environment and increase customer value.
Illustrative Method
Referring now to
In the event that it is determined (decision 903) that the dispensing head does not need to be primed, the fluid-dispensing device may then proceed (step 909) with operations.
However, if it is determined (decision 903) that the dispensing head does need to be primed, the dispensing head die is heated (step 905). This heating may cause gaseous bubbles disposed within the dispensing head and elsewhere in the fluid-dispensing system to increase in surface area, thus facilitating the removal of the gaseous bubbles from the dispensing head through orifices in the dispensing head.
The dispensing head die may be heated (step 905) using thin film resistors or other heating elements disposed within the fluid-dispensing device. Furthermore, temperature input from a temperature sensor may be used to control the heating of the dispensing head die such that fluid and gaseous bubbles in the general vicinity of the die are heated to a desired temperature or range of temperatures. For example, the fluid and gaseous bubbles may be heated to a temperature that is greater than the ambient temperature of the device, but less than the boiling point of the fluid.
The fluid and gaseous bubbles are then expelled (step 907) through the dispensing head orifices until the gaseous bubbles are substantially eliminated from the dispensing head. This may be done using a fluid pressurization system, a pump, and/or gravity. The fluid-dispensing device may then proceed (step 909) with operations.
The preceding description has been presented only to illustrate and describe embodiments and examples of the principles described. This description is not intended to be exhaustive or to limit these principles to any precise form disclosed. Many modifications and variations are possible in light of the above teaching.
This application claims the benefit of U.S. Provisional patent application Ser. No. 61/024817, filed on 30 Jan. 2008, which is hereby incorporated by reference in its entirety.
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