Thermal ink jet printhead extended droplet volume control

Abstract

A method and apparatus for controlling the volume of ink droplets ejected from printhead nozzles over a larger printhead operating temperature range. Each nucleating electrical pulse applied to the heating elements in the printhead to eject an ink droplet is preceded by a plurality of non-nucleating pre-pulses. Based upon the printhead temperature sensed, a controller selects the pre-pulse width and time width between pre-pulses from a look-up table.

Description

BACKGROUND OF THE INVENTION

This invention relates to thermal ink jet printing devices and more particularly to thermal ink jet printheads having an extended operating temperature range over which the volume of ejected ink droplets may be controlled.

In the thermal ink jet printing process, a short duration voltage pulse is applied to the heating elements of the printhead, which raises the surface of the heating elements very rapidly. The ink in the neighborhood of the heating element is superheated and a vapor bubble is nucleated at the heating element surface. The bubble begins to expand under the influence of the high initial vapor pressure and continues to expand due to inertial effects, ejecting an ink droplet from the printhead nozzles. The pressure inside the bubble immediately begins to decrease because of the evaporation at the ink vapor interface with the heating element surface. The evaporation process extracts heat from the heated ink and the ink temperature slowly decreases. To some extent, the growth of the bubble and, therefore, the associated volume of the ejected ink droplet depend on the amount of energy available in the ink near the ink vapor interface. Only a small fraction of the input energy of the voltage pulse is utilized in nucleating the bubble and ejecting the ink droplet, the rest of the input energy goes into the printhead and its heat sink. As a result, the printhead temperature increases as the printing process continues. The higher printhead temperature causes an increase in the volume of the ejected ink droplet. Since the droplet volume is one of the variables that determines printed image quality, the quality of the printed image can change as the printhead temperature changes. Accordingly, one of the approaches to control the droplet volume is to modify the input energy to the heating elements, as the printhead temperature changes.

U.S. Pat. No. 4,490,728 discloses one practice currently in use, wherein a two part electrical pulse is applied to the heating elements of a thermal ink jet printer. The pulses comprise a single precursor pulse insufficient to vaporize the ink, followed by a nucleation pulse the produce the bubble and eject an ink droplet. A certain time delay is incorporated between the two pulses. The purpose of the precursor pulse or pre-pulse is to preheat the ink near the heating elements to provide additional energy to the bubble when it nucleates during the main pulse.

U.S. Pat. No. 5,107,276 discloses a thermal ink jet printhead that is maintained at a substantially constant, but higher than ambient, operating temperature during printing. To prevent printhead temperature fluctuations during printing, the heating elements not being used to eject ink droplets are selectively energized with electrical pulses having insufficient magnitude to vaporize ink.

U.S. Pat. No. 5,036,337 discloses a method and apparatus for controlling the volume of ink droplets ejected from thermal ink jet printheads. The electrical signals applied to the heating elements for generating droplet ejecting bubbles thereon are composed of packets of electrical pulses. The number of pulses per packet and the width and spacing therebetween are controlled in order to maintain the desired volume of the ejected ink droplets.

When a single pre-pulse is used, the duration of the pre-pulse determines the maximum temperature reached by the ink during the pre-pulse time. If this value is too high, that is, the pre-pulse is too long, nucleation is prematurely initiated which interferes with the main nucleation pulse causing droplet ejection failure. If the appropriate pre-pulse time is used, so that interference with the main pulse does not occur, the pre-pulse width or time is decreased as the printhead temperature is increased, eventually resulting in no pre-pulse before the main pulse. Thus, a single pre-pulse offers a measure of droplet volume control, but only over a relatively small temperature range of about 15° C. Though some droplet volume control is available by prior art techniques, it is important to be able to provide droplet volume control over an extended temperature range.

SUMMARY OF THE INVENTION

It is an object of the present invention to provide an ink jet printhead having an extended temperature range over which the volume of the ejected ink droplets may be controlled.

In one aspect of the invention, there is provided a method for extending the temperature range over which the volume of ejected ink droplets from nozzles of a thermal ink jet printhead may be controlled, the printhead having a selectively addressable heating element for each nozzle to produce momentary ink vapor bubbles that eject an ink droplet when the heating elements are addressed with an ink-nucleating electrical pulse in response to data signals received by the printhead, the method comprising the steps of: sensing the temperature of the printhead; applying a plurality of non-nucleating electrical pre-pulses to the selected heating elements in response to data signals received; applying a nucleating pulse to each of the selected heating elements subsequent to the plurality of non-nucleating pre-pulses to eject ink droplets from the printhead nozzles; providing clocking signals having predetermined units per time period; and controlling the number of non-nucleating pre-pulses, the pre-pulse width, and time width between pre-pulses based upon a look-up table established to take into account the printhead temperature, the pre-pulse width and time width being variable multiple whole units of clock signals to maintain the desired droplet volume.

In one embodiment of the invention, a thermal ink jet printhead for ejecting ink droplets from nozzles therein to a recording medium in response to image data signals has a means for extending the temperature range over which the volume of the ejected droplets may be controlled, comprising: a plurality of selectively addressable heating elements, one for each nozzle, the heating elements each producing a momentary ink vapor bubble when addressed with an ink-nucleating electrical pulse representative of an image data signal; a temperature sensor; a power supply; and a control circuit for applying a plurality of non-nucleating electrical pre-pulses to selected heating elements in response to data signals received and a nucleating electrical pulse to the selected heating elements subsequent to the pre-pulses to eject ink droplets from the printhead nozzles, the control circuit including a clocking device, a controller with a look-up table, and drivers for applying electrical pulses to the heating elements, each pre-pulse width and time width between pre-pulses being predetermined whole numbers of clocking units generated by the clocking device, the look-up table containing pre-pulse widths and time widths between pre-pulses based upon the printhead temperature, the controller for selecting the pre-pulse widths and time widths between pre-pulses from the look-up table in order to maintain the desired droplet volume during a printing operation by the printhead when the printhead temperature changes.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described by way of example with reference to the accompanying drawings, wherein like reference numerals refer to like elements and in which:

FIG. 1 is a cross-sectional view of a printhead containing the present invention;

FIG. 2 is a block diagram of a circuit for energizing the heating elements of the printhead of FIG. 1 ;

FIG. 3 is plot of the temperature at the ink interface with the heating elements versus time, ink energy versus time, and superheat versus time for a single pre-pulse firing scheme as disclosed in the prior art;

FIG. 4 is a plot of the temperature at the ink interface with the heating elements versus time, ink energy versus time, and superheat versus time for a multiple pre-pulse firing scheme of the present invention; and

FIG. 5 is a plot of the droplet mass versus voltage for a single nucleating pulse, a single pre-pulse and nucleating pulse, and a multiple pre-pulse and nucleating pulse firing scheme.

DESCRIPTION OF THE PREFERRED EMBODIMENT

In FIG. 1 , a schematic cross-sectional view of a thermal ink jet printhead 10 is shown of the type disclosed in U.S. Pat. No. 4,774,530, the relevant portions of which are incorporated herein by reference. This view is along the length of one of a plurality of ink flow channels 20 in the printhead, and places the nozzles in communication with the printhead reservoir 24 . The printhead is composed of a silicon upper substrate or channel plate 31 aligned and bonded to a silicon lower substrate or heating element plate 28 , with an intermediate insulative thick film layer 18 sandwiched therebetween. The thick film layer is patterned to expose the heating elements 34 , electrode contact pads 32 , and to provide a flow-through passageway 38 , which connects the reservoir 24 with the channels 20 . Ink (not shown) flows from the reservoir 24 through the passageway 38 and around the channel closed end 21 as depicted by arrow 23 .

In the preferred embodiment, an underglaze layer 39 , such as silicon dioxide, is deposited on the silicon heating element plate 28 prior to the forming a set of heating elements, which may be polysilicon or other well known resistive material, such as zirconium boride. Aluminum addressing electrodes 33 and common return 35 are formed, each having contact pads 32 , followed by a passivation layer 16 which is deposited over the underglaze layer and the heating elements electrodes. The passivation layer may be any suitable material, such as silicon nitride and/or reflowed polysilicon glass, and is patterned to expose the heating elements and the contact pads. A pyrolytic silicon nitride layer 17 is deposited on the exposed heating elements followed by the deposition of a tantalum layer 12 for cavitational stress protection of the pyrolytic silicon layer 17 . For additional electrode passivation, a phosphorous doped CVD silicon dioxide film (not shown) is optionally deposited over the entire heating element plate and removed from the heating elements and contact pads.

Next, an insulative thick film layer 18 , such as, for example, polyimide, is formed on the passivation layer 16 or the optional doped CVD silicon dioxide film having a thickness of 25 to 50 micrometers. The thick film layer 18 is photolithographically processed to remove those portions of the layer over each heating element, forming pits 26 which contain the heating elements, forming the passageway 38 which provide the ink flow path from the reservoir 24 to the channels 20 , and exposing the contact pads 32 .

As disclosed in U.S. Pat. No. Re. 32,572,incorporated herein by reference, the heat element plates are formed from a silicon wafer (not shown), where a plurality of sets of heating elements and their addressing electrodes are patterned and protected from the ink as described above. Then the thick film layer 18 is deposited over the passivated electrodes and heating elements and patterned as described above. The channel plates are likewise formed from a separate silicon wafer (not shown). A plurality of channel plates are produced in the wafer by orientation dependent etching one surface thereof to produce an etched-through recess for each channel plate that will serve as the reservoir 24 and its open bottom serves as the reservoir inlet 25 . A set of parallel grooves is etched in the wafer surface for each reservoir to serve as the ink channels, and the two wafers are aligned and bonded together and diced into a plurality of separate printheads 10 . The dicing operation opens one end of the grooves to form the nozzles 27 in a front face 29 of the printhead. When the wafers are aligned, the closed end 21 of the channels 20 are positioned over the passageways 38 to complete the ink flow paths from the reservoir to the nozzles, and each channel has a heating element in a pit a predetermined distance upstream from the nozzle.

The individual printheads may be mounted on a heat sink 19 and positioned adjacent a printed circuit board 22 having electrodes 14 which are connected to the contact pads 32 of the printhead addressing electrodes by wire bonds 15 . The printhead 10 shown in FIG. 1 may be used in a carriage type printer as disclosed in U.S. Pat. No. 4,571,599 or a plurality of such printheads may be placed on a full width array bar (not shown) to form a fixed page width printhead. The principal of operation of the present invention is the same for either a carriage type printer or a page width printer, so the invention will be explained with reference to a carriage type printer.

As is well known in the art, the operating sequence of the thermal ink jet systems starts with an electrical pulse through the heating elements in the ink filled channel of sufficient magnitude to substantially instantaneously vaporize the ink contacting the heating element. In order to function properly, heat transferred from the heating element to the ink must be of sufficient magnitude to super heat the ink contacting the surface of the heating element far above its normal boiling point. For water based inks, the temperature is about 280° C. The expansion of the bubble forces a droplet of ink out of the nozzle. After passage of the electrical pulse through the heating element, the heating element is no longer being heated and the bubble collapses. The entire bubble formation/collapse sequence occurs in about 30μ seconds. The channel can be refilled after 100-500 seconds dwell time to enable the dynamic refilling factors to become dampened.

As heat is added to the printhead during the printing operation, the volume and velocity of the ejected ink droplet increases. Thus, for high quality printing, the temperature of the printhead and the magnitude of the thermal energy generated by the pulsed heating element must be taken into account and controlled to maintain constant ink droplet volume and velocity.

The energy input to the heating elements can be changed by supplying a pre-pulse immediately preceding the main nucleating pulse. One practice currently in use is to provide a single pre-pulse before the main nucleating pulse. A certain time delay is incorporated between the two pulses. The power content in the pre-pulse is significantly lower than that needed for nucleation. The purpose of the pre-pulse is to preheat the ink near the heating element to provide additional energy to the bubble when it nucleates during the main pulse. A typical temperature history at the ink-heating element surface interface for a single pre-pulse firing scheme is shown in FIG. 3 , where P 1 denotes the pre-pulse duration, P 2 denotes the quiescent time between pulses, and P 3 denotes the main pulse duration. For the case shown in FIG. 3 , P 1 =0.9μ seconds, P 2 =4.7μ seconds, and P 3 =2.1μ seconds. The total pulse time is P 1 +P 2 +P 3 or 7.7μ seconds.

FIG. 3 also shows the energy stored in the ink and the superheat content of the ink. The superheat is defined as the energy in that portion of the ink that is above 1000° C. The pulse duration of the pre-pulse determines the maximum temperature reached during the pre-pulse time. If this value is too high, i.e., if the pre-pulse is too long, bubble generation during this time interferes with the droplet ejecting main nucleation and results in droplet ejection failure. When the printhead is at a lower temperature, the longest possible pre-pulse is applied which will not produce threshold nucleation of the ink, and as the printhead temperature increases, the pre-pulse duration is decreased, eventually resulting in no pre-pulse and only a main pulse. The pre-pulse durations are selected so that the droplet volume is fairly constant over the temperature range. This method provides a droplet volume control over a temperature range of about 15° C.

With a single pre-pulse method, the amount of superheat deposited in the ink is limited because there is generally a relatively long time delay required between the end of the pre-pulse and the beginning of the main pulse. Because of the P 2 in the example shown in FIG. 3 , the energy deposited in the ink is dissipated in the ink lowering the ink temperature below 100° C. at the time the main pulse P 3 is initiated. As seen from FIG. 3 , the total energy of the ink during the P 2 period is fairly constant. However, the superheat becomes zero. The superheat increases again during the main pulse. Because of this temperature response, the maximum superheat that can be deposited without causing interference with the droplet-ejecting nucleation by the main pulse is limited. Table 1, below, lists the superheat increment possible, and temperature interval for droplet volume control for the single-pre-pulse scheme.

The present invention uses a large number of short duration pre-pulses prior to the main pulse. The entire pulse train is composed of sequential bits of data provided by the controller 46 ( FIG. 2 ) which provides these data bits at intervals determined by the timing device 42 (FIG. 2 ). When a data bit from controller 46 is high, current flow in the selected heater element(s) is enabled, and when the data bit from controller 46 is low, current flow in the selected heater element(s) is prevented. Thus, the clocking period of timing device 42 determines the minimum time durations of pulse on times and pulse off times, with all pulse lengths being integer numbers of clocking periods in length.

With an input pulse train composed of a large number of short-duration pre-pulses prior to the main pulse, the ink temperature near the heating element surface is maintained above 1000° C. prior to the application of the main pulse. The duration of pre-pulses, the number of pre-pulses, total time for the pulses, and the temperature to which the ink is heated during the pre-pulsing time determine the total superheat in the ink. The higher the superheat, the higher is the droplet volume obtained at a given printhead temperature. Based upon simulation studies, the temperature range over which droplet volume control may be exercised under the multiple pre-pulsing scheme of the present invention is listed below in Table 2, where the pulsing scheme column lists the clocking period and the total length of the pulse trains. Thus, smaller clocking periods and longer pulse train lengths provide larger temperature control ranges.

TABLE 1
Single Pre-Pulse	Superheat increment	Temperature Interval for
Duration/Total Time	possible (nJ/μm 2 )	droplet volume control
0.9 μsec/7.7 μsec	0.0543	17° C.

TABLE 2
Pre-Pulsing scheme	Superheat increment	Temperature interval for
Clock Period, total time	possible (nj/μm2)	droplet volume control
200 nsec, 6.2 μsec	0.0988	30° C.
150 nsec, 8.0 μsec	0.17	53° C.

In FIG. 4 , a temperature at the ink and heating element surface interface is shown as a function of time for a multiple pre-pulsing scheme of the present invention. In this embodiment, there are eight pre-pulses and a main nucleation pulse. The first pre-pulse is 0.6 μsec on and 0.4 μsec off, the next seven pre-pulses are each 0.2 μsec on and 0.4 μsec off. The main nucleation pulse is 2.2 μsec on, with a total pulse duration on of 7.4 μsec on. At 25° C. initial printhead temperature, this particular multiple pre-pulsing scheme gives a superheat content of 0.2970 nj/μm2. The multiple pre-pulsing method in the above embodiment substantially increases the temperature range over which the droplet volume can be exercised, and the superheat content of the ink plays an important role in determining the volume of the droplet ejected by the heating element.

Droplet volume was measured at 250° C. at different voltages for a main nucleating pulse, a single pre-pulse prior to a main pulse, and multiple pre-pulses prior to a main pulse and the results are shown in FIG. 5 . From this plot, it is seen that the droplet volume obtained with a main pulse only (no pre-pulse) is about 19 picoliters (pi). With a single pre-pulse, the droplet volume is 23 pl, and with the multiple pre-pulse method, the droplet volume is 29 pl. The experimentally determined droplet volume sensitivity to temperature is 0.3 pl/° C. Using this number a single pre-pulse will have a temperature range for droplet volume control of 13° C. and the multiple pre-pulse system will have a temperature range of 33° C. Thus, a significant extension of temperature range for droplet volume control is available with the multiple pre-pulsing system of the present invention. The threshold voltage will change with printhead temperature and the initial number of pre-pulses will vary also with the printhead temperature, which is sensed by temperature sensor 30, discussed below.

Referring to FIGS. 1 and 2 , a temperature sensor 30 is attached to the surface of the heating element plate 28 opposite the surface having the heating elements and prior to mounting of the printhead on the heat sink 19 . The thickness of the temperature sensor 30 is about 1 to 10 mils or 25 to 250 μm, so that it will not interfere with the attachment of the printhead to the heat sink. The temperature sensor may be optionally located on the same surface of the heating element plate 28 that contains the heating elements 34 or on the opposite side of the heat sink as shown in dashed line. The temperature signal line 37 may be a dedicated electrode insulatively mounted on either side of the heat sink. The temperature signals from the temperature sensor is directed to the controller 46 in control circuitry 36 via line 37 . A timing device 42 , such as a digital clock, and image data signals 41 are directed to the controller. In response thereto, the controller enables the energization of selected heating elements through associated drivers 40 . The heating elements 34 are connected to a power supply 44 via line 43 and common return electrode 35 . The drivers are connected to the heating elements via addressing electrodes 33 , wire bonds 15 , and printed circuit board electrodes 14 . The drivers 40 are connected to ground through return lines 13 and cable 11 .

The electrical pulses generated by the controller in response to the image data received which energize the heating elements are a multiple pre-pulses followed by a nucleating pulse. In the preferred embodiment, the multiple pre-pulses and main pulse is as described in FIG. 4 , discussed above. The pre-pulses are of very short duration and in a preferred embodiment, are generally of the order of about 100 nanoseconds or multiples thereof. Each pulse whether a pre-pulse or main pulse and the time width between pulses are composed of widths equal to time between one or more clock units generated by the timing device. The control circuitry 36 for selectively applying electrical energy signals to the heating elements, comprising the multiple pre-pulses and main nucleation pulse, for energization thereof in response to the image data representing digitized image information, includes a controller or microprocessor 46 with look up table 51 and timing device or clock 42 . The controller is connected to each driver 40 in the array of drivers. The voltage supply 44 is connected via line 43 to the common electrode 35 of the heating elements 34 and to ground via the drivers 40 , return line 13 and cable 11 . Thus, the drivers essentially function as switches individually controlled by the controller to enable the passage of current through the heating elements. The total power applied to the heating elements is adjusted by the controller by adjusting the number of pre-pulses, the pre-pulse timewidth, and time width between pre-pulses and between the pre-pulses and the main pulse. In the preferred embodiment, the power supply provides a constant voltage and the number of pre-pulses and time widths therefor are adjusted in accordance with empirically generated data in the look up table 51 . The pre-pulse widths, time widths between pre-pulses, and the number of pre-pulses are determined and stored in the look up table based upon the temperature of the printhead by means well known in the controller industry. Therefore, the temperature of the printhead is sensed by the temperature sensor 30 and the controller uses the information about the printhead temperature to select the appropriate pre-pulse number and width from the look up table for application thereof to the heating elements by the drivers. Thus, the controller selects the appropriate pre-pulse to precede main nucleation pulse and the desired droplet volume is maintained as the printhead temperature changes during the printing operation.

Although the foregoing description illustrates the preferred embodiment, other variations are possible and all such variations as will be apparent to those skilled in the art are intended to be included within the scope of this invention as defined by the following claims.

Claims

1. A method for extending the temperature range over which the volume of ejected ink droplets from nozzles of a thermal ink jet printhead may be controlled, the printhead having a selectively addressable heating element for each nozzle to produce momentary ink vapor bubbles that eject an ink droplet when the heating elements are addressed with an ink-nucleating electrical pulse in response to data signals received by the printhead, the method comprising the steps of:sensing the temperature of the printhead; applying a plurality of non-nucleating electrical pre-pulses to the selected heating elements in response to data signals received; applying a nucleating pulse to each of the selected heating elements subsequent to the plurality of non-nucleating pre-pulses to eject ink droplets from the printhead nozzles; providing clocking signals having predetermined units per time period; and controlling the number of non-nucleating pre-pulses, the pre-pulse width, and time width between pre-pulses based upon a look-up table established to take into account the printhead temperature, the pre-pulse width and time width being independently variable multiple whole units of clock signals to maintain the desired droplet volume.

2. A thermal ink jet printhead for ejecting ink droplets from nozzles therein to a recording medium in response to image data signals and having means to extend the temperature range over which the volume of the ejected droplets may be controlled, comprising:a plurality of selectively addressable heating elements, one for each nozzle, the heating elements each producing a momentary ink vapor bubble when addressed with an ink-nucleating electrical pulse representative of an image data signal; a temperature sensor; a power supply; and a control circuit for applying a plurality of non-nucleating electrical pre-pulses to selected heating elements in response to data signals received and a nucleating electrical pulse to the selected heating elements subsequent to the pre-pulses to eject ink droplets from the printhead nozzles, the control circuit including a clocking device, a controller with a look-up table, and drivers for applying electrical pulses to the heating elements, each pre-pulse width and time width between pre-pulses being predetermined whole numbers of clocking units generated by the clocking device, the look-up table containing pre-pulse widths and time widths between pre-pulses based upon the printhead temperature, the controller for selecting the pre-pulse widths and time widths between pre-pulses from the look-up table in order to maintain the desired droplet volume during a printing operation by the printhead when the printhead temperature changes.