This disclosure relates generally to phase change ink printers, and, in particular, to ink transport systems within phase change ink printers.
In general, inkjet printers include at least one printhead configured with an array of inkjet ejectors that are operated to eject drops of liquid ink onto an image receiving surface. A phase-change inkjet printer employs phase change inks that are solid at ambient temperature, but transition to a liquid phase at an elevated temperature. The melted ink can then be ejected by the inkjet ejectors in a printhead to form an ink image on the image receiving surface. The image receiving surface may be an intermediate imaging member, such as a rotating drum or belt, on which a layer of release agent has been applied. After the ink image is formed on the release agent layer, the image is then transferred to an image receiving substrate, such as a sheet of paper, as the substrate passes through a nip formed between a transfix roller and the intermediate imaging member. In other printing systems, the ink can be ejected directly onto printing media as the media moves past the printheads.
As already noted above, phase change ink is loaded into a printer in solid form, transported to a melting device, and melted to produce liquid ink. The melted ink can be stored in a reservoir that can be either internal or external to a printhead. Some printers include both internal and external reservoirs, with the reservoir internal to the printhead(s) refilling from the external reservoir when the ink in the internal reservoir is low.
In phase change inkjet printers having multiple printheads, the ink is used at varying rates by each printhead. These varying rates of use necessitate independent refilling of the internal ink reservoir of each printhead. Previous printers used a series of ball valves, flapper valves, solenoids, pressure sources, and other mechanical hardware to enable individual refilling of each internal reservoir from the external reservoir. However, the mechanical ink transport systems can be slow at responding to changes in ink levels in the internal reservoirs, and the mechanical transport systems have a large number of parts that can malfunction. Thus, improved transport of liquid ink in a phase change ink printer is desirable.
In one embodiment an ink transport system enables accurate refilling of a second ink reservoir from a first ink reservoir with minimal moving parts. The ink transport system comprises a thermally conductive tube, a thermoelectric device, and a controller. The thermally conductive tube has a first end that is fluidly connected to a first ink reservoir and a second end that is fluidly connected to a second ink reservoir to enable transport of melted phase change ink between the first ink reservoir and the second ink reservoir. The thermoelectric device is operatively connected to the thermally conductive tube and the controller is operatively connected to the thermoelectric device. The controller is configured to selectively operate the thermoelectric device to heat the thermally conductive tube to melt phase change ink within the tube to enable the phase change ink to flow from the first ink reservoir to the second ink reservoir, and to remove heat from the thermally conductive tube to solidify the melted phase change ink within the tube to disable flow of the phase change ink from the first ink reservoir to the second ink reservoir.
In another embodiment an ink transport system enables accurate refilling of ink reservoirs internal to a plurality of printheads from a first ink reservoir with minimal moving parts. The ink transport system comprises a first ink reservoir, a plurality of printheads, a plurality of thermally conductive tubes, a plurality of thermoelectric devices, and a controller. The first ink reservoir configured to hold a supply of phase change ink, while each printhead in the plurality of printheads includes at least one internal ink reservoir. Each tube in the plurality of thermally conductive tubes has a first end that is fluidly connected to the first ink reservoir to enable melted phase change ink from the first reservoir to enter each tube in the plurality of thermally conductive tubes. Each tube in the plurality of thermally conductive tubes further includes a second end that is fluidly connected to only one of the at least one internal ink reservoir in the plurality of printheads. Each second end of each thermally conductive tube is connected to a different internal ink reservoir than the other second ends of the other thermally conductive tubes in the plurality of thermally conductive tubes to enable each tube in the plurality of thermally conductive tubes to supply melted phase change ink to only one internal ink reservoir of one printhead in the plurality of printheads. Each thermoelectric device in the plurality of thermoelectric devices is operatively connected to only one of the thermally conductive tubes and each thermoelectric device is operatively connected to a thermally conductive tube that is different than the thermally conductive tubes to which the other thermoelectric devices in the plurality of thermoelectric devices are operatively connected. The controller is operatively connected to each thermoelectric device in the plurality of thermoelectric devices. The controller is configured to selectively operate each thermoelectric device independently of the other thermoelectric devices in the plurality of thermoelectric devices to heat independently each thermally conductive tube to melt phase change ink within each tube to enable melted phase change ink to flow from the first ink reservoir to the internal ink reservoir to which the tube is fluidly connected, and to remove heat independently from each thermally conductive tube to solidify the melted phase change ink within the tube to disable flow of the phase change ink from the first ink reservoir to the internal ink reservoir to which the tube is fluidly connected.
For a general understanding of the present embodiments, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate like elements. As used herein, the terms “printer,” “printing device,” or “imaging device” generally refer to a device that produces an image with one or more colorants on print media and may encompass any such apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, or the like, which generates printed images for any purpose. Phase change ink printers use phase change ink, also referred to as a solid ink, which is in a solid state at room temperature but melts into a liquid state at a higher operating temperature.
The term “printhead” as used herein refers to a component in the printer that is configured with an array of inkjet ejectors that are operated by firing signals to eject ink drops onto an image receiving surface. The firing signals operate actuators in the inkjet ejectors to expel ink through the nozzles of the inkjet ejectors. In some embodiments, the inkjets in an array of inkjets are arranged in staggered diagonal rows across a face of the printhead. Various printer embodiments include one or more printheads that form ink images on an image receiving surface. Some printer embodiments include a plurality of printheads arranged in a print zone. An image receiving surface, such as a print medium or the surface of an intermediate member that enables formation of an ink image, moves past the printheads in a process direction through the print zone. The inkjets in the printheads eject ink drops in rows in a cross-process direction, which is perpendicular to the process direction across the image receiving surface.
The printhead 140 includes an internal reservoir 144 and an ink level sensor 148. The internal reservoir 144 is fluidly connected to a plurality of inkjets that terminate in apertures on a faceplate of the printhead 140 to enable the internal reservoir 144 to supply liquid phase change ink to the inkjets for ejection through the apertures or nozzles onto an image receiving surface. The ink level sensor 148 is operatively connected to the internal ink reservoir 144, and is configured to detect the amount of ink in the internal reservoir 144 and generate an electrical signal corresponding to the amount of ink detected. The ink level sensor 148 can be any suitable sensor for determining the amount of ink in the internal reservoir 144, for example, a float sensor, an optical sensor, a capacitive sensor, a pressure transducer, an electrical resistance sensor, a thermistor, or a thermocouple.
The thermally conductive tube 124 is operatively connected to the external and internal ink reservoirs to fluidly connect the reservoirs. The tube 124 includes a thermoelectric device 120 and a pressure source 108. In the embodiment of
The controller 180 is operatively connected to the ink level sensor 148, the thermoelectric device 120, and the pressure source 108. The controller 180 receives the electrical signal generated by the ink level sensor 148, and, based on the level of ink detected by the sensor 148, the controller 180 is configured to determine the direction or polarity of the current to be supplied to the thermoelectric device 120. For example, when the ink level in the internal reservoir is low, the controller 180 operates the thermoelectric device 120 to heat the tube, melting the ink in the tube 124. The controller is further configured to activate the pressure source 108 while the ink in the tube 124 is in a liquid state to urge the liquid ink 160 from the external reservoir 104 through the tube 124 to the internal reservoir 144 of the printhead 140. Once the reservoir is full, the controller is configured to reverse the polarity of the power supplied to the thermoelectric device 120 to remove heat from the thermally conductive tube 124, solidifying the ink in the tube 124 and blocking the flow of ink from the external reservoir 104 to the internal reservoir 144.
In operation, the amount of ink in the printhead internal reservoir 144 decreases as the printhead 140 ejects ink onto image receiving members or performs maintenance operations that use ink. The ink level sensor 148 generates a signal corresponding to the amount of ink in the internal reservoir 144 at predetermined intervals, and delivers the signal to the controller 180. Once the sensor detects that the ink level in the internal reservoir 144 is below a lower threshold, the controller activates the thermoelectric device 120 to apply heat to the thermally conductive tube 124, melting solid ink 164 that is in the thermally conductive tube 124. The controller activates the pressure source 108 to urge the liquid ink 160 from the external reservoir, through the thermally conductive tube 124, where ink has been liquefied by the thermoelectric device 120, and into the internal reservoir 144 of the printhead 140. When the ink level sensor 148 detects that the ink level in the internal reservoir 144 is above an upper threshold, the controller 180 deactivates the pressure source 108 and reverses the polarity of the electric power supplied to the thermoelectric device 120, which then removes heat from the thermally conductive tube 124. In response, the phase change ink 164 in the thermally conductive tube 124 solidifies, blocking the flow of ink through the tube 124.
The external reservoir 204 is configured to store a volume of liquid ink 260, and includes a heater (not shown) to enable ink in the external reservoir 204 to remain in a liquid state. In the embodiment of
Each of the printheads 240A-D includes an internal reservoir 244A-D and an ink level sensor 248A-D. The internal reservoirs 244A-D are each fluidly connected to a plurality of inkjets located in apertures on a faceplate of the corresponding printhead 240A-D to enable the internal reservoirs 244A-D to supply ink to the inkjets for ejection onto an image receiving surface. Each ink level sensor 248A-D is operatively connected to one of the internal ink reservoirs 244A-D, and is configured to detect the amount of ink in the corresponding internal reservoir 244A-D and generate an electrical signal indicative of the amount of ink in the internal reservoir 244A-D.
The thermally conductive tubes 224A-D fluidly connect the external ink reservoir 204 with internal ink reservoirs 244A-D, respectively. The thermoelectric devices 220A-D of the illustrated embodiment are thermoelectric coolers, also known as Peltier devices, which include alternating P-type and N-type semiconductors electrically connected in series in a manner known in the art to enable the devices to pull heat from one side of the device and expel the heat from the other side of the thermoelectric device when an electric current is applied through the device. The thermoelectric devices 220A-D are reversible, such that reversing the direction of the current applied to the devices 220A-D reverses the direction of heat flow through the device 220A-D. The thermoelectric devices 220A-D are positioned to enable one side to contact the corresponding thermally conductive tube 224A-D, while the other side of the device 220A-D is connected to a heat sink. As noted above, in some configurations, the thermoelectric devices can be connected to the ink reservoir or open to ambient air on the other side of the device. Thus, application of an electric current having a first polarity through the thermoelectric devices 220A-D removes heat from the heat sink and heats the corresponding thermally conductive tube 224A-D, while application of an electric current having a polarity opposite to the first polarity removes heat from the thermally conductive tubes 224A-D and expels heat into the heat sink.
The controller 280 is operatively connected to the ink level sensors 248A-D, the thermoelectric devices 220A-D, and the pressure source 208. The controller 280 receives the electrical signal generated by each of the ink level sensors 248A-D, and, based on the level of ink detected by the sensors 248A-D, individually and independently determines the polarity of the power to supply to each of the thermoelectric devices 220A-D. When the controller 280 operates any of the thermoelectric devices 220A-D to heat one of the thermally conductive tubes 224A-D, the controller 280 is configured to activate the pressure source 208 and generate an elevated air pressure in the external reservoir 204 to enable flow of the liquid ink 260 from the external reservoir 204 toward the internal reservoirs 244A-D. The controller can be configured to activate the pressure source 208 immediately, or the controller can be programmed to delay before activating the pressure to enable the ink in the tube to melt before activating the pressure source. In another embodiment, the pressure source 208 can be active at all times when the printer is on. In some embodiments, the pressure source can be a fluid pressure source, for example, a gear pump, to urge ink from the external reservoir toward the internal reservoirs.
In operation, the amount of ink in the printhead internal reservoirs 244A-D decreases as the corresponding printhead 240A-D ejects ink onto image receiving surface(s) or performs maintenance operations that use ink. The amount of ink in each of the reservoirs 244A-D decreases at differing rates, depending on the amount of ink ejected by each printhead 240A-D, necessitating individual and independent control of the ink supplied to each printhead reservoir 244A-D. Each of the ink level sensors 248A-D generates a signal corresponding to the amount of ink in the corresponding internal reservoir 244A-D at predetermined intervals, and the signals are delivered to the controller 280. When one of the sensors 248A-D detects that the ink level in the corresponding internal reservoir 244A-D is below a lower threshold, the controller activates the corresponding thermoelectric device 220A-D to apply heat to the thermally conductive tube 224A-D and melt solid ink present in the corresponding thermally conductive tube 224A-D. The controller activates the pressure source 208 to urge the liquid ink 260 from the external reservoir 204, through the thermally conductive tube(s) 224A-D where ink has been liquefied by the heated thermoelectric device 220A-D, and into the internal reservoir 244A-D that the sensor 248A-D indicated as being low. When the ink level sensor 248A-D corresponding to the heated thermoelectric device 220A-D detects that the ink level in the internal reservoir 244A-D is above an upper threshold, the controller 280 reverses the polarity of the electric power supplied to the heated thermoelectric device 220A-D, which then begins cooling the corresponding thermally conductive tube 224A-D. The phase change ink in the cooled thermally conductive tube 224A-D solidifies, blocking the flow of ink through the tube and terminating the refill process.
Each of the printheads 340A-D includes an internal reservoir 344A-D and an ink level sensor 348A-D. The internal reservoirs 344A-D are each fluidly connected to a plurality of inkjets located in apertures on a faceplate of the corresponding printhead 340A-D to enable the internal reservoirs 344A-D to supply ink to the inkjets for ejection onto an image receiving surface. Each ink level sensor 348A-D is operatively connected to one of the internal ink reservoirs 344A-D, and is configured to detect the amount of ink in the corresponding internal reservoir 344A-D and generate an electrical signal indicative of the amount of ink in the internal reservoir 344A-D.
The thermally conductive tubes 324A-D fluidly connect the external ink reservoir 304 with the corresponding internal ink reservoirs 344A-D. Each tube 324A-D includes a thermoelectric device 320A-D configured to remove heat from one side of the device and expel heat from the other side of the device when current is applied through the thermoelectric device. The thermoelectric devices 320A-D are positioned to enable one side to contact the corresponding thermally conductive tube 324A-D, while the other side of the device 320A-D is coupled to a heat sink. As noted above, in some configurations, the thermoelectric devices can be connected to the ink reservoir or open to ambient air on the other side of the device. Application of an electrical current having a first polarity through the thermoelectric devices 320A-D removes heat from the heat sink and applies heat to the corresponding thermally conductive tube 324A-D, while application of an electric current having a polarity opposite to the first polarity removes heat from the thermally conductive tube 324A-D and transfers heat to the heat sink.
The controller 380 is operatively connected to the ink level sensors 348A-D and the thermoelectric devices 320A-D. The controller 380 receives the electrical signals generated by the ink level sensors 348A-D, and, based on the level of ink detected by the sensors 348A-D, individually determines the polarity of the power supplied to each of the thermoelectric devices 320A-D.
In operation, the amount of ink in the printhead internal reservoirs 344A-D decreases as the corresponding printhead 340A-D ejects ink onto image receiving members or performs maintenance operations that use ink. The amount of ink in each of the reservoirs 344A-D decreases at differing rates, depending on the amount of ink ejected by each printhead 340A-D, necessitating individual control of the ink supplied to each printhead reservoir 344A-D. Each of the ink level sensors 348A-D generates a signal at predetermined intervals corresponding to the amount of ink in the corresponding internal reservoir 344A-D, and the signals are delivered to the controller 380. When one of the sensors 348A-D detects that the ink level in the corresponding internal reservoir 344A-D is below a lower threshold, the controller 380 activates the corresponding thermoelectric device 320A-D to apply heat to the thermally conductive tube 224A-D, melting solid ink that is in blocking the corresponding thermally conductive tube 324A-D. In the embodiment shown in
Operation and control of the various components and functions of the ink transport system are performed with the aid of the controller. The controller can be implemented with general or specialized programmable processors that execute programmed instructions. The instructions and data required to perform the programmed functions are stored in memory associated with the processors or controllers. The processors, their memories, and interface circuitry configure the components of the system to perform the functions described above and the processes described below. The controller components can be provided on a printed circuit card or provided as a circuit in an application specific integrated circuit (ASIC). Each of the circuits can be implemented with a separate processor or multiple circuits can be implemented on the same processor. Alternatively, the circuits can be implemented with discrete components or circuits provided in VLSI circuits. Also, the circuits described herein can be implemented with a combination of processors, ASICs, discrete components, or VLSI circuits.
The process 400 begins with the controller receiving a signal from the sensor in the internal reservoir indicating an amount of ink in the internal reservoir (block 410). The controller then determines whether the amount of ink in the internal reservoir is below the lower threshold (block 420). If the amount is below the lower threshold, then the controller activates the thermoelectric device to generate heat in the tube (block 430), melting the ink in the tube and enabling ink to flow from the external reservoir to the internal reservoir, as described above. In the embodiment of
It will be appreciated that variations of the above-disclosed and other features, and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims.
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Number | Date | Country | |
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20140104333 A1 | Apr 2014 | US |