Patent Application
20170253032
The following disclosure relates to the field of printing, and in particular, to inkjet heads used in printing.
Inkjet printing is a type of printing that propels drops of ink (also referred to as droplets) onto a medium or substrate, such as paper. The core of an inkjet printer includes one or more print heads (referred to herein as inkjet heads) having multiple ink channels arranged in parallel to discharge droplets of ink. A typical ink channel includes a nozzle, a chamber, and a mechanism for ejecting the ink from the chamber and through the nozzle, which is typically a piezoelectric actuator connected to a diaphragm. To discharge a droplet from an ink channel, a drive circuit provides a drive waveform to the piezoelectric actuator of that ink channel that includes a jetting pulse. In response to the jetting pulse, the piezoelectric actuator generates pressure oscillations inside of the ink channel to push the droplet out of the nozzle. The drive waveforms provided to individual piezoelectric actuators control how droplets are ejected from each of the ink channels.
In an attempt to reduce the size of inkjet heads, the ink channels within the inkjet heads are moved closer together. Also, Drop on Demand (DoD) printing is moving towards higher productivity and quality, which requires small droplet sizes ejected at high jetting frequencies. The print quality delivered by an inkjet head depends on ejection or jetting characteristics, such as droplet velocity, droplet mass (or volume/diameter), jetting direction, etc. Temperature of an inkjet head or the ink in the inkjet head may influence ink viscosity and piezo capacitance, which in turn affects the jetting characteristics. It is therefore desirable to mitigate the effects of temperature variations across an inkjet head to achieve high quality printing.
Embodiments described herein use the piezoelectric actuators to impart heat into the inkjet head. A conventional inkjet head may include heaters that are embedded into the head. However, the heaters may not be embedded in such a way to provide a uniform temperature distribution across the inkjet head. The embodiments described herein are able to provide a uniform temperature distribution across or throughout an inkjet head by selectively firing piezoelectric actuators in the inkjet head. A drive circuit provides non-jetting pulses to the piezoelectric actuators that cause the piezoelectric actuators to actuate, but do not cause jetting of droplets from the ink channels. The piezoelectric actuator converts the electrical energy from the non-jetting pulses into heat, but will not cause droplets to be ejected from its corresponding ink channel. The drive circuit may selectively provide these non-jetting pulses to piezoelectric actuators in the inkjet head to produce a uniform temperature distribution across the inkjet head.
One embodiment is a system that includes an inkjet head comprising a plurality of ink channels that jet droplets of a liquid material onto a medium using piezoelectric actuators. The system further includes a jetting pulse generator configured to provide jetting pulses to the piezoelectric actuators to jet the droplets from the ink channels. The system further includes a temperature controller comprising a non-jetting pulse generator configured to provide non-jetting pulses to at least one of the piezoelectric actuators to generate heat. The non-jetting pulses cause the at least one of the piezoelectric actuators to actuate without jetting a droplet from its corresponding ink channel.
In another embodiment, the non-jetting pulses have a pulse width that is longer than the jetting pulses.
In another embodiment, a pulse width of the non-jetting pulses is between a first set of resonant frequencies of the ink channels, and a second set of resonant frequencies of the ink channels.
In another embodiment, the non-jetting pulse generator is configured to apply the non-jetting pulses to the at least one of the piezoelectric actuators that have not been used for a threshold time period.
In another embodiment, the temperature controller further includes sensor elements configured to monitor a temperature in the inkjet head. The non-jetting pulse generator is configured to provide the non-jetting pulses to at least one of the piezoelectric actuators responsive to a determination that the temperature in the inkjet head is below a threshold.
In another embodiment, the sensor elements are embedded in the inkjet head, and each sensor element is associated with a different region of the inkjet head. The non-jetting pulse generator is configured to identify a region of the inkjet head where the temperature in the region is below the threshold, to identify the at least one of the piezoelectric actuators located in the region of the inkjet head, and to provide the non-jetting pulses to the at least one of the piezoelectric actuators located in the region of the inkjet head.
In another embodiment, the non-jetting pulse generator is configured to increase a number of the non-jetting pulses provided to the at least one of the piezoelectric actuators to increase the heat generated by the at least one of the piezoelectric actuators, and to decrease the number of the non-jetting pulses provided to the at least one of the piezoelectric actuators to decrease the heat generated by the at least one of the piezoelectric actuators.
In another embodiment, the non-jetting pulse generator is configured to increase an amplitude of the non-jetting pulses to increase the heat generated by the at least one of the piezoelectric actuators, and to decrease the amplitude of the non-jetting pulses to decrease the heat generated by the at least one of the piezoelectric actuators.
Another embodiment comprises a method of operating an inkjet head comprising a plurality of ink channels that jet droplets of a liquid material onto a medium using piezoelectric actuators. The method includes providing jetting pulses to the piezoelectric actuators to jet the droplets from the ink channels, and providing non-jetting pulses to at least one of the piezoelectric actuators to generate heat. The non-jetting pulses cause the at least one of the piezoelectric actuators to actuate without jetting a droplet from its corresponding ink channel.
Another embodiment comprises a system that includes a temperature controller coupled to an inkjet head, where the inkjet head includes plurality of ink channels that jet droplets of a liquid material onto a medium using piezoelectric actuators. The temperature controller includes a non-jetting pulse generator configured to provide non-jetting pulses to at least one piezoelectric actuator to generate heat in the inkjet head without jetting droplets from its corresponding ink channel.
The above summary provides a basic understanding of some aspects of the specification. This summary is not an extensive overview of the specification. It is intended to neither identify key or critical elements of the specification nor delineate any scope particular embodiments of the specification, or any scope of the claims. Its sole purpose is to present some concepts of the specification in a simplified form as a prelude to the more detailed description that is presented later.
Some embodiments of the present disclosure are now described, by way of example only, and with reference to the accompanying drawings. The same reference number represents the same element or the same type of element on all drawings.
The figures and the following description illustrate specific exemplary embodiments. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the embodiments and are included within the scope of the embodiments. Furthermore, any examples described herein are intended to aid in understanding the principles of the embodiments, and are to be construed as being without limitation to such specifically recited examples and conditions. As a result, the inventive concept(s) is not limited to the specific embodiments or examples described below, but by the claims and their equivalents.
In this example, inkjet head 100 includes a housing 202, a series of plates 203-206, and a piezoelectric device 208. Housing 202 is a rigid member to which the plates 203-206 attach to form inkjet head 100. Housing 202 includes an opening 210 for piezoelectric device 208 to pass through and interface with a diaphragm plate 203. Housing 202 further includes one or more grooves 212 on a surface that faces plates 203-206 for supplying ink to the ink channels. Groove 212 includes one or more holes 213 that are in fluid communication with an ink reservoir.
The plates 203-206 of inkjet head 100 are fixed or bonded to one another to form a laminated plate structure, and the laminated plate structure is affixed to housing 202. The laminated plate structure includes the following plates: an orifice plate 206, one or more chamber plates 205, a restrictor plate 204, and diaphragm plate 203. Orifice plate 206 includes a plurality of nozzles 220 that are formed in one or more rows. Chamber plate 205 is formed with a plurality of chambers 221 that correspond with the nozzles 220 of orifice plate 206. The chambers 221 are each able to hold ink that is to be ejected out its corresponding nozzle 220. Restrictor plate 204 is formed with a plurality of restrictors 222. The restrictors 222 fluidly connect chambers 221 to the ink supply, and control the flow of ink into chambers 221. Diaphragm plate 203 is formed with diaphragms 223 and filter sections 224. Diaphragms 223 each comprise a sheet of a semi-flexible material that vibrates in response to actuation by piezoelectric device 208. Filter sections 224 remove foreign matter from ink entering into the ink channels.
Piezoelectric device 208 includes a plurality of piezoelectric actuators 230; one for each of the ink channels. The ends of piezoelectric actuators 230 contact diaphragms 223 in diaphragm plate 203. An external drive circuit (e.g., electronics 104) is able to selectively apply drive waveforms to piezoelectric actuators 230, which vibrate the diaphragm 223 for individual ink chambers. The vibration of diaphragms 223 causes ink to be ejected or jetted from its corresponding nozzle 220. Inkjet head 100 can therefore print desired patterns by selectively “activating” the ink channels to discharge ink out of their respective nozzles.
Piezoelectric actuator 230 is the actuating device for ink channel 302 to jet a droplet. Piezoelectric actuator 230 converts electrical energy directly into linear motion. To jet from ink channel 302, a drive waveform is provided to piezoelectric actuator 230 with one or more jetting pulses. A jetting pulse causes a deformation, physical displacement, or stroke of piezoelectric actuator 230, which in turn acts to deform a wall of chamber 310. Deformation of the chamber wall generates pressure waves inside ink channel 302 that are able to jet a droplet from ink channel 302 (when specific conditions are met). A standard jetting pulse is therefore able to cause a droplet to be jetted from ink channel 302 with the desired properties when ink channel 302 is at rest.
The following provides an example of jetting a droplet from an ink channel using jetting pulse 500, such as from ink channel 302 in
Temperature of an inkjet head may affect the jetting characteristics. Therefore, it is desirable to have a uniform temperature distribution across the inkjet head so that jetting characteristics are likewise uniform for each of the ink channels. To produce a uniform temperature distribution across the inkjet head, the piezoelectric actuators in the inkjet head are used to convert electrical energy into heat. If a region of the inkjet head is “cool”, then specialized waveforms are provided to piezoelectric actuators in that region to generate heat without causing those piezoelectric actuators to jet ink. A more detailed description of this concept is described below.
Drive circuit 601 includes a jetting pulse generator 602 and a temperature controller 604. Jetting pulse generator 602 comprises a circuit, firmware, or component that generates drive waveforms for piezoelectric actuators 630 of inkjet head 620, where the drive waveforms include jetting pulses. A “jetting pulse” is defined as a pulse that causes a droplet to be jetted from an ink channel 622 with the desired properties. Jetting pulse generator 602 is configured to selectively provide the jetting pulses to ink channels 622 to discharge ink onto a medium.
Temperature controller 604 comprises a circuit, firmware, or component that adjusts, modifies, or changes the temperature across inkjet head 620. Temperature controller 604 includes a non-jetting pulse generator 606. Non-jetting pulse generator 606 comprises a circuit, firmware, or component that generates heating waveforms for piezoelectric actuators 630 of inkjet head 620, where the heating waveforms include non-jetting pulses. A “non-jetting pulse” is defined as a pulse that causes a piezoelectric actuator of an ink channel to actuate or fire, but does not cause a droplet to be jetted from the ink channel. For example, the pulse width of a non-jetting pulse may be longer than a jetting pulse so that a droplet is not jetted from the ink channel. In an inkjet head with a jetting frequency of about 30 kHz, the pulse width of a standard jetting pulse may be about 6 microseconds. At a pulse width of 6 microseconds, the pressure waves in an ink channel combine and peak at the nozzle to jet a droplet from a nozzle. If the non-jetting pulse has a pulse width between about 12-14 microseconds in a 30 kHz head, then the pressure waves can destructively interfere with one another in the ink channel so that the combined pressure wave is not large enough to jet a droplet from the ink channel.
Temperature controller 604 may also include sensor elements 608 in one embodiment. Sensor elements 608 comprise circuits, firmware, or components that measure or monitor a temperature in inkjet head 620. One or more of sensor elements 608 may be attached to or embedded within inkjet head 620, and provide temperature data for inkjet head 620 to temperature controller 604. For example, sensor elements 608 may comprise thermocouples that are embedded within inkjet head 620. Sensor elements 608 may be distributed along a length (and width) of inkjet head 620 so that the temperature may be monitored at different regions of inkjet head 620.
In step 802, jetting pulse generator 602 provides drive waveforms to inkjet head 620 under normal printing operations. Jetting pulse generator 602 provides jetting pulses to piezoelectric actuators 630 in selected ink channels 622 in inkjet head 620 to form an image on a medium. The jetting pulses sent to selected ink channels 622 cause piezoelectric actuators 630 in the selected ink channels 622 to jet a droplet.
There may be uneven jetting patterns in inkjet head 620 during printing operations, which causes some of ink channels 622 in inkjet head 620 to be dormant for a time period. Thus, some regions of inkjet head 620 may be cooler than others causing an uneven temperature distribution across inkjet head 620. Additionally, environmental conditions within a printer may cause an uneven temperature distribution across inkjet head 620. Uneven temperature distribution can negatively affect the jetting characteristics of inkjet head 620.
To create a more uniform temperature distribution, non-jetting pulse generator 606 provides one or more non-jetting pulses to piezoelectric actuators 630 in inkjet head 620 (step 804). In response to the non-jetting pulses, piezoelectric actuators 630 convert the electric energy of the pulses to heat without jetting a droplet from their corresponding ink channels. Therefore, piezoelectric actuators 630 are able to increase the temperature of inkjet head 620 without actually jetting ink onto the medium. Non-jetting pulse generator 606 may adjust the amount of heat generated by piezoelectric actuators 630 so that a target heat is reached. For example, non-jetting pulse generator 606 may increase the number of non-jetting pulses sent to piezoelectric actuators 630 to increase the heat generated by piezoelectric actuators 630, or may decrease the number of non-jetting pulses sent to piezoelectric actuators 630 to decrease the heat generated by piezoelectric actuators 630. Non-jetting pulse generator 606 may additionally or alternatively increase the amplitude of the non-jetting pulses to increase the heat generated by piezoelectric actuators 630, or may decrease the amplitude of the non-jetting pulses to decrease the heat generated by piezoelectric actuators 630. Non-jetting pulse generator 606 is able to selectively provide the non-jetting pulses to piezoelectric actuators 630 in inkjet head 620 to change the temperature across inkjet head 620.
Non-jetting pulse generator 606 may determine which piezoelectric actuators 630 to send non-jetting pulses based on a variety of factors. For example, non-jetting pulse generator 606 may apply non-jetting pulses to piezoelectric actuators 630 in ink channels 622 that have not been used for a threshold time period. Non-jetting pulse generator 606 may apply non-jetting pulses to piezoelectric actuators 630 in regions that are known to have lower temperatures based on testing or environmental conditions. Non-jetting pulse generator 606 may apply non-jetting pulses to piezoelectric actuators 630 based on data from sensor elements 608, which is further described in
Non-jetting pulse generator 606 may provide the non-jetting pulses to piezoelectric actuators 630 that are inactive for a printing operation. For example, non-jetting pulse generator 606 may communicate with jetting pulse generator 602 to identify which ink channels 622 are being used for a print operation. Non-jetting pulse generator 606 may then select other ink channels that are not being used for print operations, and use these ink channels for heating the inkjet head 620.
The parameters of the non-jetting pulse may be determined based on the jetting characteristics of an inkjet head.
Any of the various components shown in the figures or described herein may be implemented as hardware, software, firmware, or some combination of these. For example, a component may be implemented as dedicated hardware. Dedicated hardware elements may be referred to as “processors”, “controllers”, or some similar terminology. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” or “controller” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, a network processor, application specific integrated circuit (ASIC) or other circuitry, field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), non-volatile storage, logic, or some other physical hardware component or module.
Also, a component may be implemented as instructions executable by a processor or a computer to perform the functions of the component. Some examples of instructions are software, program code, and firmware. The instructions are operational when executed by the processor to direct the processor to perform the functions of the element. The instructions may be stored on storage devices that are readable by the processor. Some examples of the storage devices are digital or solid-state memories, magnetic storage media such as a magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media.
Although specific embodiments were described herein, the scope of the invention is not limited to those specific embodiments. The scope of the invention is defined by the following claims and any equivalents thereof.
