BACKGROUND OF THE INVENTION
[0001] This invention relates to a modified ink jet printing head and to a method for effectively
and efficiently producing printed images from an ink composition on a printing medium.
[0002] Ink jet printers having one or more ink jet printheads with one or more ink jetting
nozzles in each printhead for projecting drops of ink onto paper or other printing
substrates to generate graphic images and text have become increasingly popular. To
form color images, ink jet printers with multiple ink jetting nozzles are used, with
each nozzle being supplied with ink of a different color. These colored inks are then
applied, either alone or in combination, to the printing medium to make a finished
color print. Typically, all of the colors needed to make the print are produced from
combinations of cyan, magenta and yellow inks. Black ink may also be added to the
above ink combination for printing textual material or for producing true four-color
prints.
[0003] In common arrangements, the print medium is attached to a rotating drum or is advanced
in a typewriter-like mechanism past the printheads with the ink jet heads being mounted
on a traveling carriage that traverses the drum axially or, on the typewriter-like
mechanism, in a boustrophedon manner. As the heads scan a helical or boustrophedan
path over the printing medium, ink drops are projected from a minute external nozzle
in each head toward the printing medium so as to form an image on the printing medium.
A suitable control system synchronizes the generation of ink drops with the rotating
drum or typewriter-like mechanism.
[0004] Various systems and methods are known for producing printed images on a recording
substrate with aqueous based inks. A serious problem in printing images with ink jets
that use aqueous based inks is wetting of the ink discharge surface. The presence
of ink deposits on the ink discharge surface surrounding the drop discharge nozzle
causes non-uniform ink ejection from the system which in turn degrades the quality
of the printed image. Thus, methods have been provided which treat the discharge surface
of an ink jet system with non-wetting materials thereby preventing deposits of ink
from spreading out across the discharge surface from the drop discharge nozzles of
the ink jet system. Thus, in U.S. 4,533,569, the interior surface area of a glass
nozzle was cleaned with hydrofluoric acid and then coated with a blocking agent such
as ethylene glycol, glycerine and the like. Anti-wetting compounds such as long chain
anionic non-wetting agents were applied to the fluid nozzles after ionic pretreatment
to improve ink drop quality. U.S. 4,623,906 describes a three-layer coating for glass
or silicon ink jet nozzles comprising silicon nitride and/or aluminum nitride. In
U.S. Patent 4,343,013, the nozzle plate of an ink jet printer, which is made of glass,
is coated with a material which is non-wetting relative to the aqueous characteristics
of the ink composition. Compositions such as tetrafluoroethylene or certain silicone
based materials are useful for this purpose since they have these aforementioned non-wetting
characteristics. In U.S. Patent 4,368,476 a liquid repellant film layer of a fluorosilicon
non-wetting compound is provided on the surface area surrounding the jet nozzle.
In U.S. 4,643,948, an ink jet nozzle plate is coated with a non-wetting film comprising
a partially fluorinated alkyl silane and a perfluorinated alkane, respectively. In
U.S. 4,728,393, a nozzle plate of the electrostatic ink jet printer is polished to
a mirror finish and then is completely coated with a thin layer of Teflon® resin.
However, in this case, the Teflon® coating is employed for electrostatic control,
not for ink drop formation. Ink drop formation is facilitated by the air-assist and
mesa mechanisms. For this reason, the ink jet would work without the Teflon® coating.
Other articles related to the wettability per se of fluorocarbon polymeric films include
articles entitled "Highly Non-Wettable Surface of Plasma Polymer Vapor Deposition
of Tetrafluoroethlyene" by B.D. Washo, in the IBM TDB, Vol. 26, No. 4, Pg. 2074, and
"Wettablility of Perfluorcarbon Polymer Films: Effect of Roughness" by A.J.G. Allan,
et al, in Journal of Polymer Science, Vol. XXXIX, Pg. 1.
[0005] In a different ink jet printing technology, non-aqueous, phase-change inks have
been employed in place of aqueous based inks in ink jet systems. A phase change ink
is solid at room temperature but becomes liquid at the operating temperature of the
ink jet so that it may be jetted on a recording substrate in a predetermined pattern
therefrom. The jetted ink pattern solidifies on the recording substrate. The problem
of non-uniform ink drop ejection due to surface wetting as described above with respect
to aqueous based inks can also be a problem with respect to phase change inks. This
problem can conceptually and in practice be overcome by specifically configuring the
structure of the ink jet nozzle. Some examples are mesas, ink puddles, squeeze tubes,
and dissimilar liquid puddles. However, these configurations can be more costly to
fabricate than is desirable, particularly for devices consisting of arrays of jets.
[0006] Therefore a need exists for an ink jet print head from which repeatable, uniform
drops can be formed from ink compositions, including phase change ink compositions,
and in turn in which the desired printed image characteristics can be formed on the
printing medium without the need for a costly ink jet nozzle design.
SUMMARY OF THE INVENTION
[0007] This invention meets the foregoing need for an ink jet printing head in which the
previously-described desired ink drop properties can be produced from phase change
ink compositions. By employing the method and system of the present invention, the
essential printed image characteristics can be formed on a printing medium without
the need for costly reconfiguring of the design of the phase change ink jet nozzle.
More specifically, the printed images produced from phase change ink compositions
by the method and the ink jet printing head of the present invention are undegraded
and have excellent acuity because of the well formed and accurately placed ink drops.
[0008] In aqueous-based ink jet systems, ink drop quality can be improved by reducing the
wettability of the discharge surfaces of the ink jet heads. This is accomplished by
coating these surfaces with materials which inherently exhibit a significantly lower
surface energy than the aqueous-based inks. The low surface energy of the coating
material results in a relatively high ink contact angle which is well above the minimum
angle required for reducing surface wettability near the ink discharge nozzle. Therefore,
in the case of aqueous based inks, the conditions can be readily achieved for the
production of high quality ink drops.
[0009] Applicants have now recognized that the large surface energy difference between many
coating materials and aqueous-based inks, i.e., at least about 20 dynes/cm, do not
inherently exist between these coatings and phase change inks. Therefore, most coating
materials that substantially reduce discharge surface wettability for aqueous based
inks will not perform similarly with phase change inks.
[0010] It has now been discovered by applicants that the above-described images can be formed
with a phase change ink composition using an ink jet head having a nozzle plate that
defines at least one discharge nozzle which does not have to be specifically configured.
This is accomplished by increasing the ink contact angle in the area surrounding the
discharge nozzles to a predetermined level thereby preventing substantial surface
wetting of the surrounding area by the phase change ink composition. This ink contact
angle is increased by applying a layer of a selected coating material to the discharge
surface of the ink jet head. By coating the discharge surface according to the teachings
of the present invention, individual drops of the phase change ink fluid composition
having a substantially uniform size and shape can be ejected in a predetermined pattern
thereby forming thereon substantially undegraded, accurately placed printed images.
[0011] Thus, a method is provided for modifying an ink printing jet head as described above
which comprises applying a layer of a coating material to the printing jet head surface
area surrounding each said discharge nozzle. This coated surrounding surface area
has an increased phase change ink contact angle of at least about 50°, at an operating
temperature of at least about 70°C. The coated material is treated on the coated surrounding
area for maintaining a high ink contact angle in the area surrounding the discharge
nozzles. Thus, upon prolonged exposure of the surrounding area to the ink composition
at an the operating temperture, the contact angle is at least about 20% greater than
the ink contact angle for the surrounding area without treatment of the coated material.
This prevents substantial surface wetting of the surrounding area by the ink composition.
In this way, the ink printing jet head is capable of ejecting a plurality of above-described
individual drops of the phase change ink composition for forming undegraded, accurately
placed printed images on a printing medium.
[0012] The foregoing and other objects, features and advantages of the invention will become
more readily apparent from the following detailed description of a preferred embodiment
which proceeds with reference to the drawings.
DESCRIPTION OF THE DRAWINGS
[0013]
FIG. 1 is a vertical sectional view of an ink jet head modified in accordance with
the present invention.
FIG. 2 is a perspective view of an electron beam evaporation system employed to apply
the coating material to the ink jet head of this invention.
FIG. 3 is a graphical representation of ink drop repetition rate vs. time-of-travel
of the ink drops to a point 1 mm. from discharge nozzle for ink jet heads with and
without the application of selected coating material.
DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT
[0014] Referring now to FIG. 1, an ink jet head 10 for printing a phase change ink composition
onto a printing medium is depicted. The ink jet head 10 includes a body portion 12
within which a single compartment ink chamber 14 is provided. The ink chamber 14 is
enclosed by a plate 16 which forms a chamber wall. The outer portion of the nozzle
plate 16 forms a discharge surface 15. An external ink jet drop discharge nozzle defined
by nozzle plate 16, which forms the surrounding area for discharge nozzle 20, passes
from the ink chamber 14 to the exterior of the ink jet head 10. Although a single
nozzle 20 can be provided in the nozzle plate 16, a plurality of discharge nozzles
and associated ink chambers are preferably furnished. Ink chamber 14, comprised of
sections 22 and 24, is, but need not be, of generally circular cross sectional configuration.
Section 24 is positioned adjacent to the wall 16 and the external ink nozzle 20, and
is bounded by an interior wall 26 of ink jet head body 12. Section 22 is of greater
diameter than section 24, and is bounded by an interior wall 28. The sections 22,
24 as depicted are, but need not be, symmetrical about the axis 30.
[0015] A melted phase change ink is delivered to an ink receiving inlet 32, flows through
an ink passageway 34, and fills the ink chamber 14 within ink jet head 10. The end
of ink chamber 14 opposite to external ink nozzle 20 is closed by a flexible membrane
38, such as of stainless steel. A piezoelectric ceramic disc 36, metalized on both
sides and bonded to membrane 38, comprises one form of a pressure pulse generating
actuator. However, other configurations using piezoelectric ceramics can be used herein.
In response to electrical pulses applied across the piezoelectric disc, a pressure
pulse is generated in ink chamber 14. This causes the ejection of an ink drop from
the ink external nozzle 20. Ink drops are propelled towards the printing medium where
they create the requisite printed image.
[0016] The discharge surface 18 of the nozzle plate 16 has a layer of coating material 50
selectively applied to the ink jet head in the area surrounding, as well as into,
discharge nozzle 20 for purposes of preventing substantial surface wetting of the
surrounding area by the drops of the phase change ink composition being discharged
from the nozzle 20.
[0017] Through the use of surface coating layer 50, surface wetting is substantially decreased
and the contact angle of the ink composition on the coating is substantially increased.
Typically, the contact angle is measured using the procedure described in ASTM D724-45.
Furthermore, the contact angle is substantially maintained on prolonged exposure of
the surrounding area to the phase change ink composition at the phase change ink operating
temperature, typically at an operating temperature of at least about 70°C, preferably
at least about 100°C, and most preferably at least about 150°C. Thus, the contact
angle of the ink composition produced by employing the present invention with respect
to the coating layer 50 is maintained at least about 50°, preferably at least about
55°, and more preferably at least about 60°. Coating materials were evaluated by measuring
the contact angle of the phase change inks after soaking (or aging) the coating materials
in the phase change inks at the 150°C temperature for a period of time of at least
24 hours. The angle between a given phase change ink and coating material was measured
with a goniometer manufactured by Rame'-Hart Inc, bearing Model No. 100-00-115.
[0018] In order to maximize the contact angle, a minimum difference should be maintained
between the surface energy of the coating material and the surface tension of the
phase change ink composition, respectively. More specifically, the surface energy
of the coating material is preferably lower than the surface energy of the phase change
ink composition by at least about 4 dynes/cm, and more preferably at least about 6
dynes/cm. The surface energy of the coating material and the surface tension of the
phase change ink composition are preferably measured on a goniometer, such as described
above.
[0019] The material generally employed as the coating layer 50 is a polymeric material,
preferably a fluorocarbon polymer, having the requisite ink contact angle and surface
energy levels described above. The fluorocarbon polymers of choice are the Dupont
trademarked Teflon® polymers, particularly Teflon® PTFE (polytetrafluoroethylene),
Teflon® PFA (polyperfluoroalkoxybutadiene), or a fluorocarbon dispersion, such as
a dispersion of either Teflon® PTFE or PFA. The preferred dispersion is a colloidal
fluorocarbon polymer dispersed in electroless nickel, such as the above-described
Teflon® PTFE dispersed in Richardson Industries' "Dynaplate" formulations 75-A and
75-R.
[0020] Various methods can be employed for applying the coating material 50 to the ink jet
head 10. These methods can include thermal evaporation of the fluorocarbon polymers,
dip, spray or spin coating of aqueous fluorocarbon dispersions with subsequent thermal
curing, deposition of fluoropolymers onto the substrate by plasma polymerization of
precursor monomers, and deposition of inclusions of colloidal fluorocarbons in electroless
nickel. The preferred methods are the thermal evaporation of fluorocarbon resins and
the deposition of colloidal fluorocarbons in electroless nickel.
[0021] In order to better maintain a low surface energy of the coating 50 upon prolonged
ink exposure, the polymeric material is annealed by heating subsequent to deposition.
This controlled heating often takes the form of a heating cycle in which the coating
layer 50 is subjected to a plurality of individual heating steps, at a plurality of
individual annealing temperatures, for a period of time to complete the annealing
process. The preferred annealing temperature during the individual heating steps is
from about 150°C to 500°C, and more preferably from about 200°C to 400°C.
[0022] Although most phase change ink compositions can be employed within the scope of this
invention, the preferred phase change ink compositions are those which are effective
at the aforementioned elevated operating temperatures. As an example, the phase change
ink compositions can comprise a phase change ink carrier composition, preferably including
a fatty amide-containing resin material along with a tackifier and a plasticizer,
and a coloring material. The preferred fatty amide resin material is a combination
of a tetraamide compound and stearyl stearamide.
EXAMPLE 1
[0023] This example illustrates a phase change ink printing jet head apparatus of the present
invention, including a nozzle plate coated with a layer of coating material. It also
sets forth a method of this invention for producing substantially undegraded, accurately
placed phase change ink composition printed images. The subject coated apparatus is
compared to the same printing jet head having an uncoated nozzle plate.
[0024] Thus, an experiment was conducted in which the printing jet head depicted in FIG.
1, with and without a coating layer 50 of Teflon® PFA (polyperfluoroalkoxybutadiene),
applied as described in EXAMPLE 2, was employed to produce phase change ink drops.
The jet heads had identical structural geometries and were built as a layered structure
of chemically etched stainless steel plates that were bonded together into a monolithic
unit.
[0025] The jets were characterized in terms of the drop formation process and the maximum
number of drops that could be ejected per second before jet failure occurred. These
characteristics were viewed from the ink aperture to an axial location approximately
1 mm downstream of the aperture with an imaging system, an electronic delay circuit,
and a strobe light. The imaging system consisted of a microscope placed perpendicular
to the trajectory of the ink drops. This microscope was connected to a video camera
that in turn was connected to a monitor. System magnification was approximately 250X.
The strobe light backlit the drops. This unit was controlled by a delay circuit that
was triggered by the drive signal to this jet. The drive waveform that was used for
these measurements was one cycle of a sinusoidal wave with a period of 60 microseconds.
With this delay circuit, temporal measurements of the drop formation process could
be made.
[0026] A fatty amide ink composition was used which comprised the following: 39.2% of a
tetra-amide manufactured by Union Camp, 49.0% Stearyl Stearamide, 9.8% of Foral 105
tackifier manufactured by Hercules Inc., and 2% of Saniticizer 278 plasticizer manufactured
by Monsanto Company. An operating temperature of 160°C was used with each jet. The
Union Camp tetraamide is produced by the reaction of one mole of dimer acid, 2 moles
of ethylene diamine and 2 moles of stearic acid. For the coated and annealed surface,
the contact angle was at least about 60° when the ink and surface were heated to 150°C.
For the uncoated surface, the contact angle was at most about 20° at 150°C.
[0027] The voltage for each jet was set so that when each jet produced drops at a rate of
1000 drops per second, each drop reached a point one mm downstream of the nozzle in
350 microseconds. A one mm distance was chosen because it is representative of how
far the print medium is from the jet nozzle in a printer application. As the rate
of ejection was increased, any variation in either time required for the drops to
reach one mm or in the size or shape of the drops was noted.
[0028] Figure 3 is a comparison of the performance of the two jets. The graph indicates
that the jet having a discharge nozzle without a coating disposed thereon cannot produce
as many drops per second as a jet having a discharge nozzle with such a coating. At
about 2000 drops/sec., the jet without the coating failed to operate due to the meniscus
wetting over the area surrounding the nozzle. The jet with the coating operated to
more than 10,000 drops/s. For both jets, single drops were produced at every repetition
rate up to the point at which the jet failed.
[0029] The maximum drop production rate at which the jet can operate directly affects the
architecture of the print engine. The time required for a printer to produce a copy
is directly related to the number of jets that are available for printing, as well
as to the maximum number of drops per second that can be produced from each jet. If
one thinks of the data in these terms, one might conclude that for a given copy time
a printer having jets without the coating would require five times as many jets as
a printer having jets with the coating. Otherwise, the copy time for the former printer
would be about five times as great as for the latter.
[0030] The difference between the absolute maximum and absolute minimum (which defines the
range) time for the drops to reach one mm, as a function of repetition rate, also
affects print engine architecture, since this range as a function of repetition rate
is a direct measure of one type of drop placement error. This error limits the maximum,
meaningful addressability (which will be defined as the number of dot locations per
inch, where dot location refers to theoretical bit map locations rather than physical
dot locations on the media) at which the jet can be used to print. An expression for
this maximum addressability, in the direction of the printing, due to drop-time-to-media
variations can be written as:
nD = 1/(VΔt)
where n is a positive number that reflects a tolerance on drop placement, D is the
number of dot locations per inch, V is the relative velocity between the media and
jet during drop ejection, and Δt is the range of time to reach the printing medium
over the repetition rates at which the jet will print. A typical value for n might
be three for a maximum allowable drop placement error of one-third of a dot location.
If the error were larger than this, for instance, then even though the same number
of dots could be located in an inch, the information contained in these dots would
not be meaningful on the media. Therefore the maximum, meaningful addressability would
be less. From this equation, for a given n and V, as Δt increases the addressability
decreases. If the addressability is constant, one could lower the relative velocity
in order to compensate for an increase in Δt. This smaller V will result in a longer
copy time unless more jets are used to accomplish the same level of printing.
[0031] In FIG. 3, we see that the time-to-one mm increases rapidly for the uncoated jet
until the jet fails. The range of Δt for this uncoated jet is about 120 microseconds.
The range of Δt for the coated jet is only 25 microseconds. Therefore the presence
of the coating improved the Δt by about five fold. From the previous discussion, this
five fold difference in Δt means that for a given n and V, the addressability of the
coated jet is five times that of the uncoated jet. Otherwise, the copy time of the
coated jet would be five times less than that of the uncoated jet. Likewise, five
times fewer coated jets are needed to achieve the same copy time and addressability
as with the uncoated jets.
EXAMPLE 2
[0032] This example illustrates a preferred method of application of a coating material
of the present invention. Several commercial electron beam evaporators that are similar
to our system are commercially available for applying the coating layer. One such
device is the CHA Industries electron beam evaporator, Model # SE 600. As depicted
in FIG. 2, the coating material was applied to a sample coupon 70, made of stainless
steel of the type used in the manufacture of ink jet discharge heads, by an electron
beam evaporation system 60 comprising a bell jar 62 that seals onto and is supported
by base 64 in order to form an enclosed vacuum deposition chamber 66. The polymeric
coating material source was polyperfluoroalkoxybutadiene in the form of Teflon® PFA
rod 68 located in a metal holding cup 72. The deposition chamber 66 was evacuated
by a pump (not shown) in communication with chamber 66. A sample rack 74 was attached
toward the top of the bell jar 62. The sample coupon 70 was set on rack 74 immediately
above the rod 68. An electron beam source 76 was located immediately below the holding
cup 72.
[0033] The chamber 66 was evacuated to an initial pressure of about 5 X 10⁻⁶ Torr. and a
pressure during the evaporation of about 5 X 10⁻⁴ Torr. The electron beam power was
maintained during the run at about 300 watts. The sample coupons were heated to a
temperature of about 120°C by an infrared lamp 78 located above the sample coupons
within the bell jar. Though the electron beam source is located below the holder,
the beam was emitted at an angle and then focused with a magnetic field so that it
was bent into the holder. The polymeric rod 68 was heated to a range of between 300-600°C
by the electron beam source 76 which vaporized the polytetrafluoroethylene material
the vapor of which then condensed onto the sample coupon for purposes of coating same.
Coatings of about 400-600 nm thickness were obtained by this method.
[0034] The coated samples were subsequently annealed in a belt furnace under a nitrogen
atmosphere for a total period of time of about 1.75 hours over the entire cure cycle.
The belt furnace was divided into five temperature zones of substantially equal size.
Thus, the belt was driven at a constant rate of speed so that the sample has a subsequently
equal residence time in each temperature zone. The temperature in each zone can be
the same or different than an adjacent zone. In this example, the cure cycle comprises
a temperature sequence of 200°-400°-400°-400°-200° C.
[0035] The effect of a surface coating on the ink discharge surface surrounding the nozzle
of a phase change ink jet was determined by comparing the ink wetting properties of
coated and uncoated sample coupons made of stainless steel of the type used in the
manufacture of ink jet discharge heads. The wetting properties of two samples, one
PFA coated and one uncoated sample, were as follows:
a. The contact angle of the phase change ink on the annealed coated surface, measured
at 150°C, was determined to be about 68° before aging. The surface tension of the
melted phase change ink at 150°C was about 24.5 dynes/cm. The surface energy of the
unaged coated surface was determined to be 16 dynes/cm. The contact angle of the phase
change ink on the uncoated sample, measured under the same conditions, was only about
20°.
b. After aging the samples by soaking in the ink at 150°C for 72 hours, the contact
angle of the annealed coated layer surface, measured at 150°C, was determined to be
about 60°. The surface tension of the melted phase change ink at 150°C was also about
24.5 dynes/cm, and the surface energy of the aged coated surface was measured and
determined to be about 20 dynes/cm. After aging, the contact angle of the uncoated
sample, measured under the same conditions, was about 15°.
c. Samples which were coated with Teflon® PFA as described in EXAMPLE 2 above were
aged by soaking same in the ink at 150°C for 72 hours. These coated samples were not
annealed prior to aging. The contact angle of the phase change ink on these samples
was determined to be about 72 degrees before aging and 40-43 degrees after aging.
[0036] Therefore, it has been demonstrated herein that ink jet heads coated with treated
(annealed), aged fluorocarbon polymer will maintain a high contact angle, even upon
prolonged exposure to phase change inks at operating temperatures, and in turn less
degraded, more accurately placed printed images of the type previously set forth,
than their untreated counterparts.
EXAMPLE 3
[0037] EXAMPLE 2 was repeated employing a composite, coating layer of a fluorocarbon polymeric
dispersion, in this case a dispersion of the polymer in electroless nickel.
[0038] In this experiment, a commericial electroless nickel mixture was utilized in the
form of a Richardson Industries Dynaplate formulation. A boro-nickel composite was
used herein, although most of these formulations are phosphate nickel based. A mixture
of 150 ml/liter of Richardson Industries 752A preparation, 50 ml/liter of Richardson
Industries 752A preparation, and 800 ml of distilled water were mixed with 50 ml of
a DuPont 30 submicro PTFE emulsion, and were used as the coating material.
[0039] Stainless steel sample coupons were immersed in the above coating mixture at 85-90°C
for a period of 10 to 30 minutes and produced coating in the order of .0001" to .0004"
thickness. The coupons were then annealed under nitrogen at 300°C for one hour.
[0040] The contact angle of the ink on the sample before aging was 60°, and was 58° after
aging. The aging was conducted in the same manner as in EXAMPLE 2.
[0041] Therefore, it has been demonstrated that ink jet heads coated with other treated,
unaged and aged fluorocarbon polymer, and more particularly the fluorocarbon polymeric
dispersion described above, can be fabricated which will produce the requisite contact
angle, and therefore the undegraded, accurately placed printed images of the the type
previously set forth, even from phase change ink compositions.
[0042] Having illustrated and described the principles of our invention in a preferred embodiment
thereof, it should be readily apparent to those skilled in the art that the invention
can be modified in arrangement and detail without departing from such principles.
We claim all modifications coming within the spirit and scope of the accompanying
claims.