[0001] This invention relates to a non-contact cleaning of ink jet printhead cartridges
using ultrasonic transducers.
[0002] Typically, an ink jet printer has at least one printing cartridge from which droplets
of ink are directed towards a receiver. Within the cartridge, the ink may be contained
in a plurality of channels and energy pulses are used to cause the droplets of ink
to be ejected on demand or continuously, from nozzles in a plate in an orifice structure.
[0003] In a thermal ink jet printer, the energy pulses are generally provided by a set of
electrical resistors, each located in a respective one of the channels, each one of
them is individually addressable by current pulses to instantaneously heat and form
a droplet or bubble in the channels which contact the resistors. Operation of thermal
ink jet printer is described in details in US-A-4,849,774; US-A-4,500,895; and US-A-4,794,409.
[0004] On the other hand, a piezoelectric ink jet printing system includes a body of piezoelectric
material defining a plurality of parallel open topped channels separated by walls.
The walls have metal electrodes on opposite sides thereof to form shear mode actuators
for causing droplets to expel from the channels. An orifice plate defining the holes
through which the ink droplets are ejected is bonded to the open end of the channels.
The electrical energy pulses are applied to the parallel electrodes causing the channels
to shear actuating the expulsion of droplets from the orifice plate. Operation of
piezoelectric ink jet print heads is described in details in US-A-5,598,196; US-A-5,311,218;
and US-A-5,248,998.
[0005] Ink jet printing cartridges, whether it is of thermal or piezoelectric kind, use
a variety of functional components, all of which must cooperate in a precise manner
to achieve maximum efficiency. One of the most important components is an orifice
plate having a plurality of openings or nozzles therein. The nozzles are usually circular
in cross section and the diameter of the nozzles may vary from 10 to 100 µm as required
by the specification of the printer. Higher the resolution of the printed output,
smaller is the ink droplet thereby requiring smaller diameter nozzles or orifices.
Ink is ejected through these openings during printing operation. To obtain defect-free
printing output, the orifice plates and nozzles must be kept clean and free of debris
and any kind of obstructions to ink flow at all times. If the orifice plate and nozzles
are not clean, many problems can occur thereby undermining the performance of the
printer. As for example, paper fibers and other debris accumulated on the orifice
plate surface and inside the nozzles can affect the quality of the printed images.
Similarly, debris can be dried ink crusts and paper dust on the orifice plate as well
as in the ink channels and the nozzles can cause the printer to perform poorly.
[0006] The foregoing problems are overcome, as described in US-A-5,300,958 by providing
"maintenance or service stations" within the main printer unit. The maintenance stations
are designed such that when the printhead ink cartridge is not operating and is in
a "parked" position, the cartridge is situated in the maintenance station outside
the printing zone. The maintenance stations have many components which are designed
to serve many functions. These functions include: (a) priming the printhead cartridge,
(b) capping the orifice plate and nozzles (openings) therein when the printhead is
not in operation, (c) wiping contaminants from the orifice plate, (d) preventing ink
from drying out in the openings of the orifice plate, and (e) providing a receptacle
for discarding the cleaned debris.
[0007] To accomplish this cleaning, the US-A-5,103,244 discloses a structure in which a
multi-blade wiper is used. The desired cleaning is performed by dragging a printhead
(cartridge) across the selected wiper blade. The wiper mechanism also includes a plurality
of resilient blades each having an octagonal shape and rotatable about an axis.
[0008] Another cleaning structure disclosed in US-A-5,300,958, includes a printhead wiper
unit consisting of a single or dual members positioned against each other to form
a capillary pathway therebetween. The cartridge includes a compartment having an opening
therethrough and an absorbent member impregnated with cleaning solution.
[0009] Still another cleaning structure is disclosed in US-A-5,287,126 which includes a
vacuum cleaner to help clean the orifice plate. The vacuum cleaner is comprised of
a top cover plate, having a plurality of air passages, that is located over a channel
surface by spacers. A vacuum means draws the pressure in the defined volume between
the top cover plate, the channel surface, and the spacers below the external pressure,
whereby air is drawn into the defined volume through the air passage. The resulting
air flow removes ink, dust and debris from the vicinity thereby keeping the cartridge
clean.
[0010] All the above mentioned prior arts have the following drawback: distortion of orifice
plate, wear and abrasion of the orifice plate surface, and inefficient cleaning of
the printhead cartridge.
[0011] It is an object of the present invention to provide improved cleaning of ink jet
printhead cartridges.
[0012] It is another object of this invention to provide a more efficient printhead cartridge
cleaning system which not only provides a wiping unit but also permits a controlled
dislodging of debris accumulated in the nozzles and the surface of the orifice plate
and thereby cleaning the printhead cartridges.
[0013] It is another object of the present invention to provide an apparatus for cleaning
an ink jet printhead cartridge which is compact, robust and efficient.
[0014] These objects are achieved in an in ink jet printing apparatus for receiving an ink
cartridge defining an orifice structure having at least one plate with a plurality
of nozzles for ejecting ink droplets onto a receiver to form an image, means for cleaning
the orifice structure of debris, comprising:
(a) at least one non-contact actuable ultrasonic transducer operatively associated
with and spaced from the nozzles;
(b) means for actuating the non-contact actuable ultrasonic transducer to cause such
non-contact actuable ultrasonic transducer to produce ultrasonic sound waves which
impinge upon the orifice structure and dislodges debris; and
(c) means for wiping the orifice structure to clean it of loosened debris.
[0015] Advantages of the invention include:
Overcoming many of the disadvantages of the existing technology, such as damages of
the orifice plates and orifices due to wear, abrasion and distortion.
Cost-effective electronic integration of the non-contact actuable ultrasonic transducer
to the ink jet printhead cartridge.
Use of solvents and other undesirable chemicals can be avoided.
The non-contact actuable ultrasonic transducers can be miniaturized and easily accommodated
in a conventional maintenance station of a printer.
[0016] It is an important feature of the present invention to involve at least one non-contact
actuable ultrasonic transducer in conjunction with an ink jet cartridge and resilient
wipers for effectively cleaning the ink jet printhead cartridge of debris.
FIG 1 is a perspective of an ink jet printer depicting the prior art;
FIG. 2. is a partial isometric view of the maintenance station area of the ink jet
printer containing the non-contact actuable ultrasonic transducer of this invention;
FIG. 3 is an end view of an ink jet cartridge adjacent to an non-contact actuable
ultrasonic transducer; and
FIG.4 is an enlarged partial isometric view of actuator platform.
[0017] Referring to Fig. 1, a typical ink jet printer 100 of prior art is described. Ink
jet printer 100 is of the type in which the printing is done in a substantially horizontal
plane, includes a printer housing 10, a printhead carriage 20, a carriage rod 32 (see
FIG. 2), drive roller assembly 34, paper supply 38, and maintenance station 40. A
wiper platform 30 containing plurality of wipers is provided in close proximity to
the maintenance station 40. Drive roller assembly 34 feeds paper, or other print media
of choice supplied to it from the paper supply 38 to a printing zone disposed between
printhead carriage 20 and the platen (not shown) in a manner well known to artisans.
Printhead carriage 20 travels back and forth on carriage rod 32 (see FIG. 2) through
the printing zone. Printhead carriage 20 is moved bi-directionally typically by means
of a drive belt 50 connected to a carriage motor 60. Printhead carriage 20 includes
ink cartridges 64 and 66 (only two cartridges are shown here) which are connected
by a flexible electrical interconnect strip 31 to a microprocessor 24 which also controls
carriage motor 60. A control panel 70 is electrically associated with microprocessor
24 for selection of various options relating to printing operation. Such control operation
and the printing mechanism of an ink jet printer is well known in the prior art and
hereby form no part of this invention.
[0018] The present invention provides an apparatus for cleaning an ink jet printhead cartridge
which uses a high frequency non-contact actuable ultrasonic transducer in conjunction
with a plurality of conventional wipers for effectively cleaning the printhead cartridge.
The non-contact actuable ultrasonic transducers can be kept in close proximity of
the cartridges intended for cleaning without having any physical contact and transmitting
the sound energy through air. Non-contact ultrasonic transducers marketed by Ultran
Laboratories in Boalsburg, Pa. can be adapted to this cleaning operation.
[0019] Components of a typical ultrasonic cleaner include a generator or power supply that
converts conventional 50 Hz alternating current at 110 or 220 volts to greater than
10 MHz electrical energy at approximately 1,000 volts. This high frequency electrical
energy is fed to a converter where it is transformed to mechanical vibration. The
ultrasonic transducer has ceramic piezoelectric materials, for example, two or more
PZT (lead zirconate titanate) bodies of any convenient shape which, when subjected
to an alternating current, expand and contract. The piezoelectric bodies vibrate in
the longitudinal direction and this motion is transmitted to the transducer head.
[0020] The ultrasonic transducer is formed of materials having a high mechanical Q, thus
minimizing the attenuation experienced by the ultrasonic energy as it is transmitted
through this transducer. Preferably, aluminum, titanium or an aluminum or titanium
alloy having a mechanical Q greater than 50,000 is used. Examples of suitable aluminum
alloys include duralumin, aluminum alloy 7075, aluminum alloy 2024, and aluminum alloy
6061. An example of a titanium alloy which transmits ultrasonic energy efficiently
is Ti-6Al-4V. For cleaning purposes it is desirable that the wavelength, λ, of the
incident acoustic wave be of the same orders of magnitude or smaller than the nozzle
diameter so that the sound energy will penetrate the nozzle thereby dislodging debris
therein. Thus if the nozzle diameter is 20 µm the required frequency, f, of the sound
waves in air must be approximately 17 MHz as dictated by a general relationship: λf
= c, where c, the speed of sound in air, is 343 m/s at atmospheric pressure and 20
°C temperature. For the purpose of cleaning ink jet printhead cartridges, the ultrasonic
frequency must range between 5 and 30 MHz. See Fundamentals of Physics, Revised Edition
by David Halliday and Robert Resnick, John Wiley & Sons, Inc., New York (1974).
[0021] Now referring to FIG. 2, a detailed description of the maintenance station 40 of
the present invention will now be provided. The maintenance station 40 incorporates
one or more high frequency non-contact actuable ultrasonic transducers 81, 82, 83,
and 84 which transmit acoustic energy through air or gaseous medium. These ultrasonic
transducers are mounted on a transducer platform 80. Four ink jet printhead cartridges
72,74,76 and 78 which are mounted on the printhead carriage 20 are shown here to describe
fully the embodiment of the present invention. The printhead carriage 20 is moved
bi-directionally on the carriage rod 32 through the printing zone. For purposes of
the illustrative embodiment described in this invention, cartridge 72 utilizes black
ink while cartridges 74, 76, and 78 could use only cyan, yellow, and magenta ink,
respectively. The cartridges 72, 74, 76 and 78 are each provided with orifice structure
that can define ink channels but will necessarily include orifice plates 72a, 74a,
76a, and 78a respectively, through which ink droplets are ejected to a receiver. Furthermore,
any number of different colored ink cartridges could be used, as warranted by the
application of the printer. Typically, ink jet cartridges 72, 74, 76, 78 are thermal
ink jet printheads, but other kinds of cartridges, as for example, piezoelectric cartridges
may also be acceptable and useful in this invention. Each cartridge orifice structure
is provided with inlets 72b, 74b, 76b, and 78b for black, cyan, yellow, and magenta
inks respectively, being delivered from reservoirs (not shown) located somewhere else.
The maintenance station 40 is also equipped with resilient wipers 91, 92,93,94 which
are mounted on a movable wiper platform 90 for wiping off debris from the orifice
structure after ultrasonic cleaning operation of the orifice structure. The details
of the operation of the wiper is described later.
[0022] At least four wipers 91, 92, 93 and 94, as shown in FIG. 2, are provided on the movable
wiper platform 90 which is located in close proximity to the maintenance station 40.
An actuator 90a provides the bi-directional translation motion of the wiper platform
90. Wipers 91, 92, 93, 94 are equipped with actuators 91a, 92a, 93a, 94a for motion
in the vertical direction. The wiper platform 90 moves slidably on two sliding rods
22 as the actuator 90a is prompted by the microprocessor 24. Alternatively, the wiper
platform 90 can also be moved bi-directionally by a motor directly connected to the
platform 90a or through a belt. Each wiper is dedicated to orifice structure of a
specific cartridge. The microprocessor 24 (see FIG. 1) controls the motion of the
wipers 91, 92, 93 and 94 through the actuators 91a, 92a, 93a, 94a in such a manner
that a specific wiper engages in wiping action of a cartridge immediately after a
non-contact actuable ultrasonic transducer 81, 82, 83 and 84 concludes the cleaning
action of a cartridge. As for example, cartridge 72 may move across non-contact actuable
ultrasonic transducer 81 for necessary cleaning action after which is moved to wiper
91 for wiping and can be capped immediately after wiping. The wipers 91, 92, 93 and
94 and non-contact actuable ultrasonic transducers 81, 82, 83 and 84 each are dedicated
to corresponding cartridges 72, 74, 76, 78, respectively, for the purpose of eliminating
any cross contamination of debris. In other words, the non-contact actuable ultrasonic
transducers 81, 82, 83 and 84 and the actuators 90a, 91a, 92a, 93a and 94a are controlled
electronically by the microprocessor 24 through a feedback circuit (not shown).
[0023] The maintenance station 40 along with the wiper platform 90 of FIG. 2 will be understood
by those skilled in the art to be located in a region outside the printing zone at
one end of the bi-directional movement of carriage 20. Cleaning is accomplished when
the cartridges 72, 74, 76, 78 as they are moved by the carriage rod 32 until they
enter the maintenance station 40 where they engage the non-contact actuable transducers
81, 82, 83 and 84.
[0024] Referring to FIG. 3, a printhead ink cartridge 72 which includes an inlet for ink
72b and orifice plate 72a is shown in close proximity to but space from a non-contact
actuable ultrasonic transducer head 81 to provide a small air gap between the non-contact
actuable transducer head 81 and the orifice plate 72a. For sake of convenience only
a single printhead ink cartridge is shown. Also shown in FIG. 3 an electrical connector
86 which can be used for quickly connecting the non-contact actuable ultrasonic transducer
85 to a power supply 84a.
[0025] Referring to FIG. 4, a detailed description of the wiper platform 90, includes the
actuator 90a for horizontal bi-directional motion of a wiper base 48 and an actuator
91a for vertical motion of the wiper 91, is given. For sake of convenience only a
single wiper 91 is shown. The wiper 91 shown in FIG. 4 has a razor like edge 43a for
effective wiping action, but other shapes can also be applicable in this invention.
The wiper 91 is mounted on a base 44 which is fastened to the actuator shaft 45. The
wiper base 48 is moved bi-directionally by the actuator 90a and the motion is controlled
by the microprocessor 24 (see FIG. 1). Other alternative means may be used to move
the platform such as a motor directly connected to the wiper base 48 or through a
belt or a lead screw (not shown).
PARTS LIST
[0026]
- 10
- printer housing
- 20
- printhead carriage
- 22
- sliding rod
- 24
- microprocessor
- 30
- wiper platform
- 31
- electrical interconnect strip
- 32
- carriage rod
- 34
- drive roller assembly
- 38
- paper supply
- 40
- maintenance station
- 43a
- wiper edge
- 44
- wiper base
- 45
- transducer shaft
- 48
- wiper base
- 50
- drive belt
- 60
- drive motor
- 64
- ink cartridge
- 66
- ink cartridge
- 70
- control panel
- 72
- black ink cartridge
- 72a
- orifice plate for black ink
- 72b
- inlet for black ink
- 74
- cyan ink cartridge
- 74a
- orifice plate for cyan ink
- 74b
- inlet for cyan ink
- 76
- yellow ink cartridge
- 76a
- orifice plate for yellow ink
- 76b
- inlet for yellow ink
- 78
- magenta ink cartridge
- 78a
- orifice plate for magenta ink
- 78b
- inlet for magenta ink
- 80
- ultrasonic transducer platform
- 81
- non-contact ultrasonic transducer
- 82
- non-contact ultrasonic transducer
- 83
- non-contact ultrasonic transducer
- 84
- non-contact ultrasonic transducer
- 84a
- power supply
- 86
- electrical connector
- 90
- movable wiper platform
- 90a
- actuator
- 91
- wiper
- 91a
- actuator
- 92
- wiper
- 92a
- actuator
- 93
- wiper
- 93a
- actuator
- 94
- wiper
- 94a
- actuator
- 100
- ink jet printer