PATENT ABSTRACT
A method of priming a printhead in an inkjet printer, the printhead having a nozzle face defining an array of nozzles for ejecting ink on to a media substrate fed past the printhead in a media feed direction, by providing a pad having a contact face dimensioned so that it can encompass all the nozzles in the array, moving the pad such that the contact face engages the nozzle face to cover the array of nozzles, forcing ink into the printhead under pressure until ink flows out the nozzles in the array and, withdrawing the pad such that the contact face disengages the nozzle face.

PATENT DESCRIPTION
FIELD OF THE INVENTION 
       [0001]    The present invention relates to be field of printers and in particular pagewidth inkjet printers. 
       CO-PENDING APPLICATIONS 
       [0002]    The following applications have been filed by the Applicant simultaneously with the present application: 
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         [0003]    The disclosures of these co-pending applications are incorporated herein by reference. The above applications have been identified by their filing docket number, which will be substituted with the corresponding application number, once assigned. 
       CROSS REFERENCES 
       [0004]    The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference. 
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       BACKGROUND OF THE INVENTION 
       [0005]    The Applicant has developed a wide range of printers that use pagewidth printheads instead of traditional reciprocating printhead designs. The pagewidth designs increase print speeds as the printhead does not traverse back and forth across the page to deposit a line of an image. The pagewidth printhead simply deposits the ink on the media as it moves past at high speeds. Such printheads have made it possible to perform 1600 dpi resolution printing at speeds in the vicinity of 60 pages per minute; speeds previously not attainable with conventional inkjet printers. The high print speeds require a large ink supply flow rate. Not only are the flow rates higher but distributing the ink along the entire length of a pagewidth printhead is more complex than feeding ink to a relatively small reciprocating printhead. To address the many issues associated with supplying ink to a pagewidth printhead, the Applicant has developed an active fluidic system which gives the user control of the ink flow through the printhead. The active fluidic system is described in detail in the applicant scope pending application U.S. Ser. No. ______ (Our docket: SBF01US), the contents of which is incorporated herein by cross-reference. The active fluidic system connects the pagewidth printhead to an ink supply reservoir via a pump or pressure pulse generator. The pagewidth printhead is also connected to a waste ink outlet or sump. While the active fluidic system can correct problems such as nozzle deprime, air bubbles, nozzle face floods and de-cap clogging, it will not fix “dead” nozzles that simply burn out or otherwise fail over the life of the printhead. 
         [0006]    In light of this, many of the Applicant&#39;s printers provide the printhead has a user removable and replaceable cartridge. Providing the pagewidth printhead as a user removable cartridge allows the user to periodically replace the printhead and hence maintain the print quality without replacing the entire printer. This recognizes that individual ink ejection nozzles may fail over time and eventually there are enough dead nozzles to cause artifacts in the printed image. However, every time a printhead cartridge is replaced, it needs to be primed with ink. Priming is notoriously wasteful as the ink is typically forced through the nozzles until the entire printhead structure has purged any air bubbles. In the time it takes for the air to be cleared from the multitude of conduits extending through the printhead, a significant amount of ink has been wasted. 
       SUMMARY OF THE INVENTION 
       [0007]    Accordingly, the present invention provides a method of priming a printhead in an inkjet printer, the printhead having a nozzle face defining an array of nozzles for ejecting ink on to a media substrate fed past the printhead in a media feed direction, the method comprising the steps of: 
         [0008]    providing a pad having a contact face dimensioned so that it can encompass all the nozzles in the array; 
         [0009]    moving the pad such that the contact face engages the nozzle face to cover the array of nozzles; 
         [0010]    forcing ink into the printhead under pressure until ink flows out the nozzles in the array; and, withdrawing the pad such that the contact face disengages the nozzle face. 
         [0011]    Holding a pad against the nozzle array as it is being primed under pressure, significantly reduces the volume of ink purged through the nozzles. The pad partially obstructs the nozzles to constrict the flow of ink. However the flow of air out of the nozzles is much less constricted, so the overall priming process is not delayed because of the flow obstruction generated by the pad material. 
         [0012]    Preferably, the method further comprises step of wiping the nozzle face with a wiper member after the step of withdrawing the pad to disengage the contact face. In a particularly preferred form, the method further comprises step of ejecting ink from all the nozzles into a spittoon after the nozzle face has been wiped. In a further preferred form, the pad is positioned within a skirt of resilient material for sealing against the printhead to contain any ink leakage. In some embodiments, the method further comprises step of providing the printhead has a printhead cartridge for user removal and replacement from the printer. 
         [0013]    In specific embodiments, the printer has at least three ink tanks for storing the inks of different colour, the printer also having a cradle for supporting the printhead cartridge adjacent a media feed path, a fluid interface in fluid communication with the ink tanks, and a latch for securing the printhead cartridge in the cradle, the latch being movable between an open position where access to the cradle is unobstructed, and a closed position where access to the cradle is obstructed, such that the method further comprises the steps of placing the printhead cartridge in the cradle while the latch is in the open position, the printhead cartridge having a fluid coupling positioned to align with the fluid interface when placed in the cradle, moving the latch to the closed position to secure the printhead cartridge in cradle, providing a mechanical linkage between the latch and the fluid interface such that the fluid interface sealingly engages the fluid coupling upon moving the latch to the closed position, before the step of forcing ink into the printhead cartridge under pressure. 
         [0014]    Preferably, the steps of forcing ink into the printhead the printhead further comprises pumping ink from all the ink tanks to the fluid interface under pressure. Preferably, the printhead is a pagewidth printhead and the array of nozzles extends the printing width of the media substrate. Preferably, the fluid coupling is an array of spouts extending from an interface plate, and the fluid interface is a corresponding when the sockets such that step of sealingly engaging the fluid interface in fluid coupling involves moving the sockets onto the array of spouts. In a further preferred form, the cradle provides a reference surface of contacting the datum the printhead cartridge such that the nozzle face is precisely spaced from the media feed path. In a particularly preferred form, the printhead cartridge has a first fluid coupling and a second fluid coupling, and the printer has a first fluid interface and a second fluid interface, the first fluid interface being in fluid communication with the ink tanks and second fluid interface being in fluid communication with a waste ink outlet, the first fluid coupling for sealingly engaging the first fluid interface, and the second fluid coupling for sealingly engaging the second fluid interface. Preferably the printer has support structure with a first and second bearing surface positioned in the cradle for contacting the printhead cartridge, the first bearing surface being aligned with any compressive force applied to the printhead cartridge by the first fluid interface as it engages the first fluid coupling, and the second bearing surface being aligned with any compressive force applied to the printhead cartridge by the second fluid interface as it engages the second fluid coupling. In a particularly preferred form, the support structure has a third bearing surface of aligned with any compressive force applied to the printhead cartridge by the latch as it secures the cartridge in the cradle. 
         [0015]    In a particularly preferred form, the step of priming the printhead cartridge further comprises providing a wiper member in the printer, moving the wiper member into the media feed path, and wiping all the nozzles in the nozzle face with a single traverse of the wiper member in a direction parallel to the media feed direction. 
         [0016]    Preferably, the wiper member is rotated about an axis extending transverse to the media feed direction when it is moved into the media feed path and traversed across the nozzle face. Preferably, the printhead is a pagewidth printhead and the array of nozzles is elongate and extends the printing width of the media substrate such that the wiper member also extends the length of the nozzle array. Preferably, the method further comprises the steps of providing the spittoon within a print platen, the print platen having a profiled guide surface for directing sheets of the media substrate past the printhead and a central recessed portion, the spittoon having an absorbent elements positioned in the central recessed portion of the print platen. Preferably, the print platen is moved into the media feed path and presented to the printhead by rotating it about the axis extending transverse to the media feed direction under which the wiper member rotates. Preferably, the wiper member and the print platen are fixed to a chassis mounted on the printer for rotation about the axis is transverse to the media feed direction. In a further preferred form, a capper for capping the array of nozzles when the printer is not in use, is also fixed to the chassis. Optionally, a primer for servicing the nozzle array when the printhead primes with ink, is also fixed to the chassis. 
         [0017]    Optionally, an additional spittoon is fixed to the chassis for use during an extended ink purge from the printhead. Optionally, the wiper member is rotated about the axis transverse to media feed direction at variable speeds. Optionally, the wiper member is selectively rotated in either direction about the axis transverse to the media feed direction. In a particularly preferred form, the chassis is mounted towards an away from the nozzle face. Preferably, the chassis is moved by the application of equal forces to bearing points in the chassis that are equidistantly positioned from the longitudinal mid-point of the wiper member. In particularly preferred form, the pagewidth printhead has a plurality of printhead ICs aligned end to end to extend transverse to the media feed direction, the printhead ICs receiving power and data from a line of wire bonds along one of the transverse sides of the printhead ICs, and the wiper member being rotated such that it moves towards the line of wire bonds. Preferably, the line of wire bonds are sealed within a bead of encapsulant, the bead of encapsulant being profiled to assist the wiper member to retain paper dust and other contaminants wiped from the nozzle face. 
         [0018]    Preferably, the wiper member has a plurality of resilient blades extending the width of media substrate. Preferably the plurality of blades is arranged in parallel rows, each of the rows extending the width of media substrate. In a further preferred form, the blades in one of the parallel rows positioned such that they are not in registration with the blades an adjacent one of the parallel rows. In particularly preferred form, blades in each of the parallel rows are spaced from their adjacent blades by a gap allowing independent movement of adjacent blades. 
         [0019]    Preferably, the step of moving the chassis is performed by a maintenance drive provided a printer, the maintenance drive having a first actuator for moving the wiper member towards away from the nozzle face, and a second actuator for rotating wiper member about the axis extending transverse to the media feed direction, the first actuator and the second actuator being independently operable. Preferably, the second actuator is configured to selectively vary the speed with which the wiper member is rotated about the axis extending transverse to the media feed direction. Conveniently, the first actuator and the second actuator are both electric motors with encoder disks providing feedback to a print engine controller in the inkjet printer. Preferably, the second actuator is reversible such that the wiper member can be rotated in both directions. 
         [0020]    Preferably, the method further comprises step of providing an absorbent pad printer removing paper dust and other contaminants on the wiper member. Preferably, method further comprises the step of providing a doctor blade in the printer such that its extends transverse to the media feed direction, wherein during use the maintenance drive moves the wiper member over the nozzle face, then across the absorbent pad and then past the doctor blade such that the resilient blade flexes in order to pass the doctor blade and upon disengagement of the resilient blade and the doctor blade, the resilient blade springs back to its quiescent shape thereby projecting contaminants from its surface. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0021]    Preferred embodiments of the invention will now be described by way of example only, with reference to the accompanying figures, in which: 
           [0022]      FIG. 1  is schematic overview of the printer fluidic system; 
           [0023]      FIG. 2A  is a perspective of the printhead cartridge of the present invention installed the print engine of a printer; 
           [0024]      FIG. 2B  shows the print engine without the printhead cartridge installed to expose the inlet and outlet ink couplings; 
           [0025]      FIG. 3  is a perspective of the complete printhead cartridge according to the present invention; 
           [0026]      FIG. 4  shows the printhead cartridge of  FIG. 3  with the protective cover removed; 
           [0027]      FIG. 5  is an exploded is a partial perspective of the printhead assembly within the printhead cartridge of  FIG. 3 ; 
           [0028]      FIG. 6  is an exploded perspective of the printhead assembly without the inlet or outlet manifolds or the top cover molding; 
           [0029]      FIG. 7  is a sectional perspective view of the print engine, the section taken through the line  7 - 7  of  FIG. 2A ; 
           [0030]      FIG. 8  is a sectional elevation of the print engine taken through line  7 - 7  of  FIG. 2A , showing the maintenance carousel drawing the wiper blades over the doctor blade; 
           [0031]      FIG. 9  is a section view showing the maintenance carousel after drawing the wiper blades over the absorbent cleaning pad; 
           [0032]      FIG. 10  is a sectional view showing the maintenance carousel being lifted to cap the printhead with the capper maintenance station; 
           [0033]      FIG. 11  is a sectional view showing the maintenance carousel being lowered in order to uncap the printhead; 
           [0034]      FIG. 12  is a sectional view showing the wiper blades wiping the nozzle face of the printhead; 
           [0035]      FIG. 13  is a sectional view showing the maintenance carousel rotated back to its initial position shown in  FIG. 8  where the wiper blades have been drawn past the doctor blade to flick contaminants of the tip region; 
           [0036]      FIG. 14  is a sectional view showing the wiper blades been drawn across the absorbent cleaning pad; 
           [0037]      FIG. 15  is a sectional view showing the maintenance carousel rotated to present the printhead capper to the printhead; 
           [0038]      FIG. 16  is a sectional view showing the maintenance carousel being lifted to present the print platen to the printhead; 
           [0039]      FIG. 17  is a sectional view showing the way that is carousel being lifted to seal the printhead ICs with the capper; 
           [0040]      FIG. 18  is a perspective view of the maintenance carousel in isolation; 
           [0041]      FIG. 19  is another perspective view of the maintenance carousel in isolation in showing the carousel drive spur gear; 
           [0042]      FIG. 20  is an exploded perspective of the maintenance carousel in isolation; 
           [0043]      FIG. 21  is a cross-sectional through an intermediate point along the carousel length; 
           [0044]      FIG. 22  is a schematic section view of a second embodiment of the maintenance carousel, the maintenance carousel presenting a print platen to the printhead; 
           [0045]      FIG. 23  is a schematic section view of the second embodiment of the maintenance carousel with the printhead priming station engaging the printhead: 
           [0046]      FIG. 24  is a schematic section view of the second embodiment of the maintenance carousel with the wiper blades engaging the printhead; 
           [0047]      FIG. 25  is a schematic section view of the second embodiment of the maintenance carousel with an ink spittoon presented to the printhead; 
           [0048]      FIG. 26  is a schematic section view of the second time of maintenance carousel with the print platen presented to the printhead as the wiper blades are cleaned on the absorbent pad; 
           [0049]      FIG. 27  is a section view of the injection moulded core used in the second embodiment of the maintenance carousel; 
           [0050]      FIG. 28  is a schematic view of the injection moulding forms being removed from the core of the second embodiment of maintenance carousel; 
           [0051]      FIG. 29  is a section view of the print platen maintenance station shown in isolation; 
           [0052]      FIG. 30  is a section view of the printhead capper maintenance station shown in isolation; 
           [0053]      FIG. 31  is a section view of the wiper blade maintenance station shown in isolation; 
           [0054]      FIG. 32  is a section view of the printhead priming station shown in isolation; 
           [0055]      FIG. 33  is a section view of a blotting station shown in isolation; 
           [0056]      FIG. 34  is a schematic section view of a third embodiment of the maintenance carousel; 
           [0057]      FIG. 35  is a sketch of a first embodiment of the wiper member; 
           [0058]      FIG. 36  is a sketch of a second embodiment of the wiper member; 
           [0059]      FIG. 37  is a sketch of a third embodiment of the wiper member; 
           [0060]      FIG. 38  is a sketch of the fourth moment of the wiper member; 
           [0061]      FIG. 39  is a sketch of the fifth embodiment of the wiper member; 
           [0062]      FIG. 40  is a sketch of the sixth embodiment of the wiper member; 
           [0063]      FIG. 41  is a sketch of the seventh embodiment of the wiper member; 
           [0064]      FIG. 42  is a sketch of the eighth embodiment of the wiper member; 
           [0065]      FIGS. 43A and 43B  sketches of a nine embodiment of the wiper member; 
           [0066]      FIG. 44  is a sketch of a 10th embodiment of the wiper member; 
           [0067]      FIG. 45  is sketch of an 11th embodiment of the wiper member; 
           [0068]      FIG. 46  is sketch of a 12 embodiment of the wiper member; 
           [0069]      FIG. 47  is the sectional perspective of the print engine without the printhead cartridge for the maintenance carousel; 
           [0070]      FIG. 48  is a perspective showing the independent drive assemblies used by the print engine; 
           [0071]      FIG. 49  is an exploded perspective of the independent drive assemblies shown in  FIG. 48 ; and,  FIG. 50  is an enlarged view of the left end of the exploded perspective showing in  FIG. 49 . 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     Printer Fluidic System 
       [0072]      FIG. 1  is a schematic overview of the fluidic system used by the print engine described in  FIGS. 2A and 2B . As previously discussed, the print engine has the key mechanical structures of an inkjet printer. The peripheral structures such as the outer casing, the paperfeed tray, paper collection tray and so on are configured to suit the specific printing requirements of the printer (for example, the photo printer, the network printer or Soho printer). The Applicant&#39;s photo printer disclosed in the co-pending application U.S. Ser. No. 11/688,863 (Our Docket No. RRE001US) is an example of an inkjet printer using a fluidic system according to  FIG. 1 . The contents of this disclosure are incorporated herein by reference. The operation of the system and its individual components are described in detail in U.S. Ser. No. 11/872,719 (Our Docket No. SBF009US) the contents of which are incorporated herein by reference. 
         [0073]    Briefly, the printer fluidic system has a printhead assembly  2  supplied with ink from an ink tank  4  via an upstream ink line  8 . Waste ink is drained to a sump  18  via a downstream ink line  16 . A single ink line is shown for simplicity. In reality, the printhead has multiple ink lines for full colour printing. The upstream ink line  8  has a shut off valve  10  for selectively isolating the printhead assembly  2  from the pump  12  and or the ink tank  4 . The pump  12  is used to actively prime or flood the printhead assembly  2 . The pump  12  is also used to establish a negative pressure in the ink tank  4 . During printing, the negative pressure is maintained by the bubble point regulator  6 . 
         [0074]    The printhead assembly  2  is an LCP (liquid crystal polymer) molding  20  supporting a series of printhead ICs  30  secured with an adhesive die attach film (not shown). The printhead ICs  30  have an array of ink ejection nozzles for ejecting drops of ink onto the passing media substrate  22 . The nozzles are MEMS (micro electromechanical) structures printing at true 1600 dpi resolution (that is, a nozzle pitch of 1600 npi), or greater. The fabrication and structure of suitable printhead IC&#39;s  30  are described in detail in U.S. Ser. No. 11/246,687 (Our Docket No. MNN001US) the contents of which are incorporated by reference. The LCP molding  20  has a main channel  24  extending between the inlet  36  and the outlet  38 . The main channel  24  feeds a series of fine channels  28  extending to the underside of the LCP molding  20 . The fine channels  28  supply ink to the printhead ICs  30  through laser ablated holes in the die attach film. 
         [0075]    Above the main channel  24  is a series of non-priming air cavities  26 . These cavities  26  are designed to trap a pocket of air during printhead priming. The air pockets give the system some compliance to absorb and damp pressure spikes or hydraulic shocks in the ink. The printers are high speed pagewidth printers with a large number of nozzles firing rapidly. This consumes ink at a fast rate and suddenly ending a print job, or even just the end of a page, means that a column of ink moving towards (and through) the printhead assembly  2  must be brought to rest almost instantaneously. Without the compliance provided by the air cavities  26 , the momentum of the ink would flood the nozzles in the printhead ICs  30 . Furthermore, the subsequent ‘reflected wave’ can generate a negative pressure strong enough to deprime the nozzles. 
       Print Engine 
       [0076]      FIG. 2A  shows a print engine  3  of the type that uses a print cartridge  2 . The print engine  3  is the internal structure of an inkjet printer and therefore does not include any external casing, ink tanks or media feed and collection trays. The printhead cartridge  2  is inserted and removed by the user lifting and lowering the latch  126 . The print engine  3  forms an electrical connection with contacts on the printhead cartridge  2  and a fluid coupling is formed via the sockets  120  and the inlet and outlet manifolds,  48  and  50  respectively. 
         [0077]    Sheets of media are fed through the print engine by the main drive roller  186  and the exit feed roller  178 . The main drive roller  186  is driven by the main drive pulley and encoder disk  188 . The exit feed roller  178  is driven by the exit drive pulley  180  which is synchronized to the main drive pulley  188  by the media feed belt  182 . The main drive pulley  188  is powered by the media feed motor  190  via the input drive belt  192 . 
         [0078]    The main drive pulley  188  has an encoder disk which is read by the drive pulley sensor  184 . Data relating to the speed and number of revolutions of the drive shafts  186  and  178  is sent to the print engine controller (or PEC). The PEC (not shown) is mounted to the main PCB  194  (printed circuit board) and is the primary micro-processor for controlling the operation of the printer. 
         [0079]      FIG. 2B  shows the print engine  3  with the printhead cartridge removed to reveal the apertures  122  in each of the sockets  120 . Each aperture  122  receives one of the spouts  52  (see  FIG. 5 ) on the inlet and outlet manifolds. As discussed above, the ink tanks have an arbitrary position and configuration but simply connect to hollow spigots  124  (see  FIG. 8 ) at the rear of the sockets  120  in the inlet coupling. The spigot  124  at the rear of the outlet coupling leads to the waste ink outlet in the sump  18  (see  FIG. 1 ). 
         [0080]    Reinforced bearing surfaces  128  are fixed to the pressed metal casing  196  of the print engine  3 . These provide reference points for locating the printhead cartridge within the print engine. They are also positioned to provide a bearing surface directly opposite the compressive loads acting on the cartridge  2  when installed. The fluid couplings  120  push against the inlet and outlet manifolds of the cartridge when the manifold spouts (described below) open the shut off valves in the print engine (also described below). The pressure of the latch  126  on the cartridge  2  is also directly opposed by a bearing surface  128 . Positioning the bearing surfaces  128  directly opposite the compressive loads in the cartridge  2 , the flex and deformation in the cartridge is reduced. Ultimately, this assists the precise location of the nozzles relative to the media feed path. It also protects the less robust structures within the cartridge from damage. 
       Printhead Cartridge 
       [0081]      FIG. 3  is a perspective of the complete printhead cartridge  2 . The printhead cartridge  2  has a top molding  44  and a removable protective cover  42 . The top molding  44  has a central web for structural stiffness and to provide textured grip surfaces  58  for manipulating the cartridge during insertion and removal. The base portion of the protective cover  42  protects the printhead ICs (not shown) and line of contacts (not shown) prior to installation in the printer. Caps  56  are integrally formed with the base portion and cover the ink inlets and outlets (see  54  and  52  of  FIG. 5 ). 
         [0082]      FIG. 4  shows the printhead assembly  2  with its protective cover  42  removed to expose the printhead ICs on the bottom surface and the line of contacts  33  on the side surface. The protective cover is discarded to the recycling waste or fitted to the printhead cartridge being replaced to contain leakage from residual ink.  FIG. 5  is a partially exploded perspective of the printhead assembly  2 . The top cover  44  has been removed reveal the inlet manifold  48  and the outlet manifold  50 . The inlet and outlet shrouds  46  and  47  have been removed to better expose the five inlet and outlet spouts ( 52  and  54 ). The inlet and outlet manifolds  48  and  50  form a fluid connection between each of the individual inlets and outlets and the corresponding main channel (see  24  in  FIG. 6 ) in the LCP molding. The main channel extends the length of the LCP molding and it feeds a series of fine channels on the underside of the LCP molding. A line of air cavities  26  are formed above each of the main channels  24 . As explained above in relation to  FIG. 1 , any shock waves or pressure pulses in the ink are damped by compressing the air the air cavities  26 . 
         [0083]      FIG. 6  is an exploded perspective of the printhead assembly without the inlet or outlet manifolds or the top cover molding. The main channels  24  for each ink color and their associated air cavities  26  are formed in the channel molding  68  and the cavity molding  72  respectively. Adhered to the bottom of the channel molding  68  is a die attach film  66 . The die attach film  66  mounts the printhead ICs  30  to the channel molding such that the fine channels on the underside of the channel molding  68  are in fluid communication with the printhead ICs  30  via small laser ablated holes through the film. 
         [0084]    Both the channel molding  68  and the top cover molding  72  are molded from LCP (liquid crystal polymer) because of its stiffness and coefficient of thermal expansion that closely matches that of silicon. It will be appreciated that a relatively long structure such as a pagewidth printhead should minimize any thermal expansion differences between the silicon substrate of the printhead ICs  30  and their supporting structure. 
       Printhead Maintenance Carousel 
       [0085]    Referring to  FIG. 7 , a sectioned perspective view is shown. The section is taken through line  7 - 7  shown in  FIG. 2A . The printhead cartridge  2  is inserted in the print engine  3  such that its outlet manifold  50  is open to fluid communication with the spigot  124  which leads to a sump in the completed printer (typically situated at the base the print engine). The LCP molding  20  supports the printhead ICs  30  immediately adjacent the media feed path  22  extending through the print engine. 
         [0086]    On the opposite side of the media feed path  22  is the printhead maintenance carousel  150  and its associated drive mechanisms. The printhead maintenance carousel  150  is mounted for rotation about the tubular drive shaft  156 . The maintenance carousel  150  is also configured for movement towards and away from the printhead ICs  30 . By raising the carousel  150  towards the printhead ICs  30 , the various printhead maintenance stations on the exterior of the carousel are presented to the printhead. The maintenance carousel  150  is rotatably mounted on a lift structure  170  that is mounted to a lift structure shaft  156  such that it can pivot relative to the remainder of the print engine  3 . The lift structure  170  includes a pair of lift arms  158  (only one lift arm is shown, the other being positioned at the opposite end of the lift structure shaft  156 ). Each lift arm  158  has a cam engaging surface  168 , such as a roller or pad of low friction material. The cams (described in more detail below) are fixed to the carousel drive shaft  160  for rotation therewith. The lift arms  158  are biased into engagement with the cams on the carousel lift drive shaft  160 , such that the carousel lift motor (described below) can move the carousel towards and away from the printhead by rotating the shaft  160 . 
         [0087]    The rotation of the maintenance carousel  150  about the tubular shaft  166  is independent of the carousel lift drive. The carousel drive shaft  166  engages the carousel rotation motor (described below) such that it can be rotated regardless of whether it is retracted from, or advanced towards, the printhead. When the carousel is advanced towards the printhead, the wiper blades  162  move through the media feed path  22  in order to wipe the printhead ICs  30 . When retracted from the printhead, the carousel  150  can be repeatedly rotated such that the wiper blades  162  engage the doctor blade  154  and the cleaning pad  152 . This is also discussed in more detail below. 
         [0088]    Referring now to  FIG. 8 , the cross section  7 - 7  is shown in elevation to better depict the maintenance carousel lift drive. The carousel lift drive shaft  160  is shown rotated such that the lift cam  172  has pushed the lift arms  158  downwards via the cam engaging surface  168 . The lift shaft  160  is driven by the carousel lift spur gear  174  which is in turn driven by the carousel lift worm gear  176 . The worm gear  176  is keyed to the output shaft of the carousel lift motor (described below). 
         [0089]    With the lift arms  158  drawing the lift structure  170  downwards, the maintenance carousel  150  is retracted away from the printhead ICs  30 . In this position, the carousel  150  can be rotated with none of the maintenance stations touching the printhead ICs  30 . It does, however, bring the wiper blades  162  into contact with the doctor blade  154  and the absorbent cleaning pad  152 . 
       Doctor Blade 
       [0090]    The doctor blade  154  works in combination with the cleaning pad  152  to comprehensively clean the wiper blades  162 . The cleaning pad  152  wipes paper dust and dried ink from the wiping contact face of the wiper blades  162 . However, a bead of ink and other contaminants can form at the tip of the blades  162  where it does not contact the surface of the cleaning pad  152 . 
         [0091]    To dislodge this ink and dust, the doctor blade  154  is mounted in the print engine  3  to contact the blades  162  after they have wiped the printhead ICs  30 , but before they contact the cleaning pad  152 . Upon contact with the doctor blade  154 , the wiper blades  162  flex into a curved shaped in order to pass. As the wiper blades  162  are an elastomeric material, they spring back to their quiescent straight shape as soon as they disengage from the doctor blade  154 . Rapidly springing back to their quiescent shape projects dust and other contaminants from the wiper blade  162 , and in particular, from the tip. 
         [0092]    The ordinary worker will appreciate that the wiper blades  162  also flex when they contact the cleaning pad  152 , and likewise spring back to their quiescent shapes once disengaged from the pad. However, the doctor blade  154  is mounted radially closer to the central shaft  166  of the carousel  150  than the cleaning pad  152 . This bends the wiper blades  162  more as they pass, and so imparts more momentum to the contaminants when springing back to the quiescent shape. It is not possible to simply move the cleaning pad  152  closer to the carousel shaft  166  to bend the wiper blades  162  more, as the trailing blades would not properly wipe across the cleaning pad  152  because of contact with the leading blades. 
       Cleaning Pad 
       [0093]    The cleaning pad  152  is an absorbent foam body formed into a curved shape corresponding to the circular path of the wiper blades  162 . The pad  152  cleans more effectively when covered with a woven material to provide a multitude of densely packed contacts points when wiping the blades. Accordingly, the strand size of the woven material should be relatively small; say less than 2 deniers. A microfiber material works particularly well with a strand size of about 1 denier. 
         [0094]    The cleaning pad  152  extends the length of the wiper blades  162  which in turn extend the length of the pagewidth printhead. The pagewidth cleaning pad  152  cleans the entire length of the wiper blades simultaneously which reduces the time required for each wiping operation. Furthermore the length of the pagewidth cleaning pad inherently provides a large volume of the absorbent material for holding a relatively large amount of ink. With a greater capacity for absorbing ink, the cleaning pad  152  will be replaced less frequently. 
       Capping the Printhead 
       [0095]      FIG. 9  shows the first stage of capping the printhead ICs  30  with the capping maintenance station  198  mounted to the maintenance carousel  150 . The maintenance carousel  150  is retracted away from the printhead ICs  30  as the lift cam  172  pushes down on the lift arms  158 . The maintenance carousel  150 , together with the maintenance encoder disk  204 , are rotated until the first carousel rotation sensor  200  and the second carousel rotation sensor  202  determine that the printhead capper  198  is facing the printhead ICs  30 . 
         [0096]    As shown in  FIG. 10 , the lift shaft  160  rotates the cam  172  so that the lift arms  158  move upwards to advance the maintenance carousel  150  towards the printhead ICs  30 . The capper maintenance station  198  engages the underside of the LCP moldings  20  to seal the nozzles of the printhead ICs  30  in a relatively humid environment. The ordinary worker will understand that this prevents, or at least prolongs, the nozzles from drying out and clogging. 
       Uncapping the Printhead 
       [0097]      FIG. 11  shows the printhead ICs  30  being uncapped in preparation for printing. The lift shaft  160  is rotated so that the lift cam  172  pushes the carousel lift arms  158  downwards. The capping maintenance station  198  moves away from the LCP molding  20  to expose the printhead ICs  30 . 
       Wiping the Printhead 
       [0098]      FIG. 12  shows the printhead ICs  30  being wiped by the wiper blades  162 . As the capping station  198  is rotated away from the printhead, the blades of the wiper member  162  contact the underside of the LCP molding  20 . As the carousel  150  continues to rotate, the wiper blades and drawn across the nozzle face of the printhead ICs  30  to wipe away any paper dust, dried ink or other contaminants. The wiper blades  162  are formed from elastomeric material so that they resiliently flex and bend as they wipe over the printhead ICs  30 . As the tip of each wiper blade is bent over, the side surface of each blade comes into wiping contact with the nozzle face. It will be appreciated that the broad flat side surface of the blades has greater contact with the nozzle face and is more effective at cleaning away contaminants. 
       Wiper Blade Cleaning 
       [0099]      FIGS. 13 and 14  show the wiper blades  162  being cleaned. As shown in  FIG. 13 , immediately after wiping the printhead ICs  30 , the wiper blades  162  are rotated past the doctor blade  154 . The function of the doctor blade  154  is discussed in greater detail above under the subheading “Doctor Blade”. 
         [0100]    After dragging the wiper blades  162  past the doctor blade  154 , any residual dust and contaminants stuck to the blades is removed by the absorbent cleaning pad  152 . This step is shown in  FIG. 14 . 
         [0101]    During this process the print platen maintenance station  206  is directly opposite the printhead ICs  30 . If desired, the carousel can be lifted by rotation of the lift cam  172  so that the nozzles can fire into the absorbent material  208 . Any colour mixing at the ink nozzles is immediately purged. Holes (not shown) drilled into the side of the tubular chassis  166  provides a fluid communication between the absorbent material  208  and the porous material  210  within the central cavity of the carousel shaft  166 . Ink absorbed by the material  208  is drawn into, and retained by, the porous material  210 . To drain the porous material  210 , the carousel  150  can be provided with a vacuum attachment point (not shown) to draw the waste ink away. 
         [0102]    With the wiper blades clean, the carousel  150  continues to rotate (see  FIG. 15 ) until the print platen  206  is again opposite the printhead ICs  30 . As shown in  FIG. 16 , the carousel is then lifted towards the printhead ICs  30  in readiness for printing. The sheets of media substrate are fed along the media feed path  22  and past the printhead ICs  30 . For full bleed printing (printing to the very edges of the sheets of media), the media substrate can be held away from the platen  206  so that it does not get smeared with ink overspray. It will be understood that the absorbent material  208  is positioned within a recessed portion of the print platen  206  so that any overspray ink (usually about one millimetre either side of the paper edges) is kept away from surfaces that may contact the media substrate. 
         [0103]    At the end of the print job or prior to the printer going into standby mode, the carousel  150  is retracted away from the printhead ICs  30  in rotated so that the printhead capping maintenance station  198  is again presented to the printhead. As shown in  FIG. 17 , the lift shaft  160  rotates the lift cam so that the lift arms  158  move the printhead capping maintenance station  198  into sealing engagement with the underside of the LCP molding  20 . 
       Printhead Maintenance Carousel 
       [0104]      FIGS. 18 ,  19 ,  20  and  21  show the maintenance carousel in isolation.  FIG. 18  is a perspective view showing the wiper blades  162  and print platen  206 .  FIG. 19  is a perspective view showing the printhead capper  198  and the wiper blades  162 .  FIG. 20  is an exploded perspective showing the component parts of the maintenance carousel, and  FIG. 21  is a section view showing the component parts fully assembled. 
         [0105]    The maintenance carousel has four printhead maintenance stations; a print platen  206 , a wiper member  162 , a printhead capper  198  and a spittoon/blotter  220 . Each of the maintenance stations is mounted to its own outer chassis component. The outer chassis components fit around the carousel tubular shaft  166  and interengage each other to lock on to the shaft. At one end of the tubular shaft  166  is a carousel encoder disk  204  and a carousel spur gear  212  which is driven by the carousel rotation motor (not shown) described below. The tubular shaft is fixed to the spur gear or rotation therewith. The printhead maintenance stations rotate together with the tubular shaft by virtue of their firm compressive grip on the shaft&#39;s exterior. 
         [0106]    The wiper blade outer chassis component  214  is an aluminium extrusion (or other suitable alloy) configured to securely hold the wiper blades  162 . Similarly, the other outer chassis components are metal extrusions for securely mounting the softer elastomeric and or absorbent porous material of their respective maintenance stations. The outer chassis components for the print platen  216  and the printhead capper  198  have a series of identical locking lugs  226  along each of the longitudinal edges. The wiper member outer chassis component  214  and the spittoon/blotter outer chassis component  218  have complementary bayonet style slots for receiving the locking lugs  226 . Each of the bayonet slots has a lug access aperture  228  adjacent a lug locking slot  230 . Inserting the locking lugs  226  into the lug access aperture  228  of the adjacent outer chassis component, and then longitudinally sliding the components relative to each other will lock them on to the chassis tubular shaft  166 . 
         [0107]    To improve the friction, and therefore the locking engagement, between each of the maintenance stations and the chassis chip shaft  166 , each of the printhead maintenance stations have an element with a curved shaft engagement surface  234 . The print platen  206  has an absorbent member  224  with a curved shaft engagement surface  234  formed on one side. The spittoon/blotter outer chassis component  218  has a relatively large absorbent spittoon/blotter member  220  which also has a curved shaft engagement surface  234  formed on its interior face. Likewise, the outer chassis component for the printhead capper  198 , and the common base of the wiper blades  162  work has curved shaft engagement surfaces  234 . 
         [0108]    The ordinary worker will appreciate that clamping the outer chassis to the inner chassis with the use of interengaging locking formations minimises the amount of machining and assembly time while maintaining fine tolerances for precisely mounting the maintenance station structures. Furthermore, the outer chassis components can be assembled in different configurations. The wiper blade outer chassis component  214  can change positions with the spittoon/blotter chassis component  218 . Similarly, the printhead capper  198  can swap with the print platen  206 . In this way the maintenance station can be assembled in a manner that is optimised for the particular printer in which it will be installed. 
       Injection Molded Polymer Carousel Chassis 
       [0109]      FIGS. 22 to 28  show another embodiment of the printhead maintenance carousel. These figures are schematic cross sections showing only the carousel and the lower portion of the printhead cartridge. It will be appreciated that the maintenance drive systems require simple and straightforward modifications in order to suit this embodiment of the carousel. 
         [0110]      FIG. 22  shows the LCP molding  20  of the printhead cartridge  2  adjacent the printhead maintenance carousel  150  with the print platen  206  presented to the printhead ICs  30 . For clarity,  FIG. 29  shows the print platen  206  in isolation. In use, sheets of media substrate are fed along the media feed path  22 . Between the nozzles of the printhead ICs  30  and the media feed path  22  is a printing gap  244 . To maintain print quality, the gap  244  between the printhead IC nozzle face and the media surface should as close as possible to the nominal values specified during design. In commercially available printers this gap is about two millimetres. However, as print technology is refined, some printers have a printing gap of about one millimetre. 
         [0111]    With the widespread popularity of digital photography, there is increasing demand for full bleed printing of colour images. “Full bleed printing” is printing to the very edges of the media surface. This will usually cause some “over spray” where ejected ink misses the edge of the media substrate and deposits on the supporting print platen. This over spray ink can then smear onto subsequent sheets of media. 
         [0112]    The arrangement shown in  FIG. 22  deals with both these issues. The paper guide  238  on the LCP molding  20  defines the printing gap  244  during printing. However the print platen  206  has a guide surface  246  formed on its hard plastic base molding. The guide surface  246  directs the leading edge of the sheets towards the exit drive rollers or other drive mechanism. With minimal contact between the sheets of media and print platen  206 , there is a greatly reduced likelihood of smearing from over sprayed ink during full bleed printing. Furthermore, placing the paper guide  238  on the LCP molding  20  immediately adjacent the printhead ICs  30  accurately maintains the gap  244  from the nozzles to the media surface. 
         [0113]    Some printers in the Applicant&#39;s range use this to provide a printing gap  244  of 0.7 millimetres. However this can be further reduced by flattening the bead of encapsulant material  240  adjacent the printhead ICs  30 . Power and data is transmitted to the printhead ICs  30  by the flex PCB  242  mounted to the exterior of the LCP molding  20 . The contacts of the flex PCB  242  are electrically connected to the contacts of the printhead ICs  30  by a line of wire bonds (not shown). To protect the wire bonds, they are encapsulated in an epoxy material referred to as encapsulant. The Applicant has developed several techniques for flattening the profile of the wire bonds and the bead of encapsulant  240  covering them. This in turn allows the printing gap  244  to be further reduced. 
         [0114]    The print platen  206  has an indentation or central recessed portion  248  which is directly opposite the nozzles of the printhead ICs  30 . Any over spray ink will be in this region of the platen  206 . Recessing this region away from the remainder of the platen ensures that the media substrate will not get smeared with wet over spray ink. The surface of the central recessed  248  is in fluid communication with an absorbent fibrous element  250 . In turn, the fibrous element  250  is in fluid communication with porous material  254  in the centre of the chassis  236  by capillary tubes  252 . Over sprayed ink is wicked into the fibrous element  250  and drawn into the porous material  254  by capillary action through the tubes  252 . 
         [0115]      FIG. 23  shows the carousel  150  rotated such that the printhead priming station  262  is presented to the printhead ICs  30 .  FIG. 30  shows the printhead priming station  272  and its structural features in isolation. The printhead priming station has an elastomeric skirt  256  surrounding a priming contact pad  258  formed of porous material. The elastomeric skirt and the priming contact pad are co-molded together with a rigid polymer base  260  which securely mounts to the injection molded chassis  236 . 
         [0116]    Whenever the printhead cartridge  2  is replaced, it needs to be primed with ink. Priming is notoriously wasteful as the ink is typically forced through the nozzles until the entire printhead structure has purged any air bubbles. In the time it takes for the air to be cleared from the multitude of conduits extending through the printhead, a significant amount of ink has been wasted. 
         [0117]    To combat this, the maintenance carousel  150  is raised so that the priming contact pad  258  covers the nozzles of the printhead ICs  30 . Holding the contact pad  258  against the nozzle array as it is primed under pressure significantly reduces the volume of ink purged through the nozzles. The porous material partially obstructs the nozzles to constrict the flow of ink. However the flow of air out of the nozzles is much less constricted, so the overall priming process is not delayed because of the flow obstruction generated by the porous material. The elastomeric skirt  256  seals against the underside of the LCP molding  22  to capture any excess ink that may flow from the sides of the contact pad  258 . Flow apertures  264  formed in the rigid polymer base  260  allows the ink absorbed by the pad  258  and any excess ink to flow to the absorbent fibrous element  250  (identical to that used by the print platen  206 ). As with the print platen  206 , ink in the fibrous element  250  is drawn into the porous material  254  within the injection molded chassis  236  by the capillary tubes  252 . 
         [0118]    By using the printhead priming station  262 , the amount of wasted ink is significantly reduced. Without the priming station, the volume of ink wasted when priming the pagewidth printhead is typically about two millilitres per colour. With the priming station  262 , this is reduced to 0.1 millilitres per colour. 
         [0119]    The priming contact pad  258  need not be formed of porous material. Instead, the pad can be formed from the same elastomeric material as the surrounding skirt  256 . In this case, the contact pad  258  needs to have a particular surface roughness. The surface that engages the nozzle face of the printhead ICs  30 , should be rough at the 2 to 4 micron scale, but smooth and compliant at the 20 micron scale. This type of surface roughness allows air to escape from between the nozzle face and contact pad, but only a small amount of ink. 
         [0120]      FIG. 24  shows the maintenance carousel  150  with the wiping station  266  presented to the printhead ICs  30 . The wiping station is shown in isolation in  FIG. 31 . The wiping station  266  is also a co-molded structure with the soft elastomeric wiper blades  268  supported on a hard plastic base  270 . To wipe the nozzle face of the printhead ICs  30 , the carousel chassis  236  is raised and then rotated so that the wiper blades  268  wipe across the nozzle face. Ordinarily, the carousel chassis  236  is rotated so that the wiper blades  268  wipe towards the encapsulation bead  240 . As discussed in the Applicant&#39;s co-pending application Docket No. RRE015US, incorporated by cross-reference above, the encapsulant bead  240  can be profiled to assist the dust and contaminants to lodge on the face of the wiper blade  268 . However, the maintenance drive (not shown) can easily be configured to rotate the chassis  236  in both directions if wiping in two directions proves more effective. Similarly, the number of wipes across the printhead ICs  30  is easily varied by changing the number of rotations the maintenance drive is programmed to perform for each wiping operation. 
         [0121]    In  FIG. 25 , the maintenance carousel  150  is shown with the printhead capper  272  presented to the printhead ICs  30 .  FIG. 32  shows the capper in isolation to better illustrate its structure. The capper  272  has a perimeter seal  274  formed of soft elastomeric material. The perimeter seal  274  is co-molded with its hard plastic base  276 . The printhead capper  272  reduces the rate of nozzle drying when the printer is idle. The seal between the perimeter seal  274  and the underside of the LCP molding  20  need not be completely air tight as the capper is being used to prime printhead using a suction force. In fact the hard plastic base  276  should include an air breather hole  278  so that the nozzles do not flood by the suction caused as the printhead is uncapped. To cap the printhead, the chassis  236  is rotated until the printhead capper  272  is presented to the printhead ICs  30 . The chassis  236  is then raised until the perimeter seal  274  engages the printhead cartridge  2 . 
         [0122]      FIG. 26  shows the inclusion of the wiper blade cleaning pad  152 . As with the first embodiment described above, the cleaning pad  152  is mounted in the printer so that the wiper blades  268  move across the surface of the pad  152  as the maintenance carousel  150  is rotated. By positioning the cleaning pad  152  such that the chassis  236  needs to be retracted from the printhead ICs  30  in order to allow the wiper blades  268  to contact pad, the chassis  236  can be rotated at relatively high speeds for a comprehensive clean of the wiper blades  268  while not risking any damaging contact with the printhead ICs  30 . Furthermore the cleaning pad  152  can be wetted with a surfactant to better remove contaminants from the wiper blades surface. 
         [0123]      FIG. 27  shows the injection molded chassis  236  in isolation. The chassis is symmetrical about two planes extending through the central longitudinal axis  282 . This symmetry is important because an injection molded chassis extending the length of pagewidth printhead, is prone to deform and bend as it cools if the cross section is not symmetrical. With a symmetrical cross-section, the shrinkage of the chassis is it cools is also symmetrical. 
         [0124]    The chassis  236  has four maintenance station mounting sockets  276  formed in its exterior surface. The sockets  276  are identical so that they can receive any one of the various maintenance stations ( 206 ,  266 ,  262 ,  272 ). In this way the maintenance stations become interchangeable modules and the order which the maintenance stations are presented to the printhead can be changed to suit different printers. Furthermore, if the maintenance stations themselves are modified, their standard sockets ensure they are easily incorporated into the existing production line with a minimum of retooling. The maintenance stations are secured in the sockets with adhesive but other methods such as an ultra sonic spot weld or mechanical interengagement would also be suitable. 
         [0125]    As shown in  FIG. 28 , the mold has four sliders  278  and a central core  288 . Each of the sliders  278  has columnar features  280  to form the conduits connecting the fibrous wicking pads to the porous material  219  in the central cavity. The line of draw for each slider is radially outwards from the chassis  236  while the core  288  is withdrawn longitudinally (it will be appreciated that the core is not a precisely a cylinder, but a truncated cone to provide the necessary draft). Injection molding of polymer components is very well suited to high-volume, low-cost production. Furthermore, the symmetrical structure of the chassis and uniform shrinkage maintain good tolerances to keep the maintenance stations extending parallel to the printhead ICs. However, other fabrication techniques are possible; for example, shock wave compressed polymer powder or similar. Furthermore, a surface treatment to increase hydrophillicity can assist the flow of ink to the capillary tubes  252  and ultimately the porous material  210  within the chassis  236 . In some printer designs, the chassis is configured for connection to a vacuum source to periodically drain ink from the porous material  210 . 
       Five Maintenance Station Embodiment 
       [0126]      FIG. 34  shows an embodiment of the printhead maintenance carousel  150  with five different maintenance stations: a print platen  206 , a printhead wiper  266 , a printhead capper  272 , a priming station  262  and a spittoon  284 . The spittoon  284  (shown in isolation in  FIG. 33 ) has a relatively simple structure—the spittoon face  284  presents flat to the printhead and has apertures (not shown) for fluid communication with the fibrous element  250  retained in its hard plastic base. 
         [0127]    The five station maintenance carousel  150  adds a spittoon  284  to allow the printer to use major ink purges as part of the maintenance regime. The four station carousel of  FIGS. 22-25 , will accommodate minor ink purges or ‘spitting cycles’ using the print platen  206  and or the capper  272 . A minor spitting cycle is used after a nozzle face wipe or as an inter-page spit during a print job to keep the nozzles wet. However, in the event that the printhead needs to be recovered from deprime, gross color mixing, large-scale nozzle drying and so on, it is likely that a major spitting cycle will be required—one which is beyond the capacity of the platen or the capper. 
         [0128]    The spittoon  284  has large apertures in its face  286  or a series of retaining ribs to hold the fibrous wicking material  250  in the hard plastic base. This keeps the fibrous element  250  very open to a potentially dense spray of ink. One face of the fibrous element  250  presses against the capillary tubes  252  to enhance the flow to the porous material  254  in the central cavity of the chassis  236 . 
         [0129]    The five socket chassis  236  is injection molded using five sliders configured at 72 degrees to each other, or six sliders at 60 degrees to each other. Similarly, a maintenance carousel with more than five stations is also possible. If the nozzle face is prone to collecting dried ink, it can be difficult to remove with a wiper alone. In these situations, the printer may require a station (not shown) for jetting ink solvent or other cleaning fluid onto the nozzle face. This can be incorporated instead of, or in addition to the spittoon. 
       Wiper Variants 
       [0130]      FIG. 35 to 46  show a range of different structures that the wiper can take. Wiping the nozzle face of printhead is an effective way of removing paper dust, ink floods, dried ink or other contaminants. The ordinary worker will appreciate that countless different wiper configurations are possible, of which, the majority will be unsuitable for any particular printer. The functional effectiveness of wiper (in terms of cleaning the printhead) must be weighed against the production costs, the intended operational life, the size and weight constraints and other considerations. 
       Single Contact Blade 
       [0131]      FIG. 35  shows a wiper maintenance station  266  with a single elastomeric blade  290  mounted in the hard plastic base  270  such that it extends normal to the media feed direction. A single wiper blade extending the length of the nozzle array is a simple wiping arrangement with low production and assembly costs. In light of this, a single blade wiper is suited to printers and the lower end of the price range. The higher production volumes favor cost efficient manufacturing techniques and straightforward assembly of the printer components. This may entail some compromise in terms of the operational life of the unit, or the speed and efficiency with which the wiper cleans the printhead. However the single blade design is compact and if it does not effectively clean the nozzle face in a single traverse, the maintenance drive can simply repeat the wiping operation until the printhead is clean. 
       Multiple Contact Blades 
       [0132]      FIGS. 36 ,  43 A,  43  and  46  show wiper maintenance stations  266  with multiple, parallel blades. In  FIG. 36 , the twin parallel blades  292  are identical and extend normal to the media feed direction. Both blades  292  are separately mounted to the hard plastic base  270  so as to operate independently. In  FIG. 46 , the blades are non-identical. The first and second blades ( 294  and  296  respectively) are different widths (or otherwise different cross sectional profiles) and durometer values (hardness and viscoelasticity). Each blade may be optimised to remove particular types of contaminant. However, they are separately mounted in the hard plastic base  270  for independent operation. In contrast, the multiple blade element of  FIGS. 43A and 43B  has smaller, shorter blades  300  all mounted to a common elastomeric base  298 , which is in turn secured to the hard plastic base  270 . This is a generally more compliant structure that has a relatively large surface area in contact with the nozzle face with each wipe. However, the thin soft blades wear and perish at a greater rate than the larger and more robust blades. 
         [0133]    With multiple parallel blades wiping across the nozzle face, a single traverse by the wiper member will collect more of the dust and contaminants. While a multiple blade design is less compact than a single blade, each wiping operation is quicker and more effective. Hence the printhead can be wiped between pages during the print job and any preliminary maintenance regime performed prior to a print job is completed in a short time. 
       Single Skew Blade 
       [0134]      FIG. 37  shows a wiper maintenance station  266  with a single blade  302  mounted in the hard plastic base  270  such that it is skew to the wiping direction. It will be appreciated that the wiping direction is normal to the longitudinal extent of the plastic base  270 . 
         [0135]    A single wiper blade is a simple wiping arrangement with low production and assembly costs. Furthermore, by mounting the blade so that it is skew to the wiping direction, the nozzle face will be in contact with only one section of blade and any time during the traverse of the wiper member. With only one section in contact with the nozzle face, the blade does not buckle or curl because of inconsistent contact pressure along its full length. This ensures sufficient contact pressure between the wiper blade and all of the nozzle face without needing to precisely line the blade so that it is completely parallel to the nozzle face. This allows the manufacturing tolerances to be relaxed so that higher volume low-cost production techniques can be employed. This may entail some compromise in terms of increasing the distance that the wiper member must travel in order to clean the printhead, and therefore increasing the time required from each wiping operation. However the reduced manufacturing costs outweigh these potential disadvantages. 
       Independent Contact Blades 
       [0136]      FIG. 38  shows a wiper maintenance station  266  with two sectioned blades  304  mounted in the hard plastic base  270 . Each of the individual blade sections  306  that make up the complete blades  304  mounted in the hard plastic base  270  for independent movement relative to each other. The individual blade sections  306  in each blade  304  are positioned so that they are out of registration with each other with respect to the wiping direction. In this way, the nozzles that are not wiped by the first blade  304  because they are positioned in a gap between two blade sections  306 , will be wiped by a blade section  306  in the second blade  304 . 
         [0137]    Wiping the nozzle face of pagewidth printhead with a single long blade can be ineffective. Inconsistent contact pressure between the blade and the nozzle face can cause the blade to buckle or curl at certain sections along its length. In these sections the contact pressure can be insufficient or there maybe no contact between the blade and the nozzle face. A wiper blade divided into individual blade sections can address this problem. Each section is capable of moving relative to its adjacent sections so any inconsistencies in the contact force, will not cause buckling or curling in other sections of blade. In this may contact pressure is maintained at the nozzle face is clean effectively. 
       Nozzle Face Wiper Having Multiple Skew Blades 
       [0138]    In  FIG. 39 , the wiper maintenance station  266  has a series of independent blades  308  mounted in the hard plastic base  270  such that they are skew to the wiping direction. The blades  308  are positioned so that the lateral extent (with respect the wiping direction) of each blade (X) has some overlap (Z) with the lateral extent of its adjacent blades (Y). By mounting the wiper blade so that it is skew to the wiping direction, the nozzle face will be in contact with only one section of blade and any time during the traverse of the wiper member. With only one section in contact with the nozzle face, the blade does not buckle or curl because of inconsistent contact pressure along its full length. This ensures sufficient contact pressure between the wiper blade and all of the nozzle face without needing to align the blade so that it is precisely parallel to the nozzle face. This allows the manufacturing tolerances to be relaxed so that high volume low-cost production techniques can be employed. A single skew blade will achieve this but it will increase the distance that the wiper member must travel in order to clean the printhead, and therefore increasing the time required from each wiping operation. In light of this, the invention uses a series of adjacent skew blades, each individual blade wiping a corresponding portion of the nozzle array. Multiple blades involve higher manufacturing costs than a single blade but in certain applications, the compact design and quicker operation outweigh these potential disadvantages. 
         [0000]    Wiper with Array of Pads 
         [0139]    In  FIGS. 40 and 44  the wiping maintenance stations  266  use an array of contact pads  310  instead of any blade configurations. The individual pads  312  maybe short squad cylinders of an elastomeric material individually mounted into the hard plastic base  270  or a cylindrical soft fibre brush similar to the format often used for silicon wafer cleaning. As discussed above, wiping the nozzle face of pagewidth printhead with a single long contact surface can be ineffective. Inconsistent contact pressure between the wiping surface and the nozzle face can cause the contact pressure to be insufficient or non-existent in some areas. 
         [0140]    Using a wiping surface that has been divided into an array  310  of individual contact pads allows each pad to move relative to its adjacent pads so any inconsistencies in the contact force will vary the amount each pad compresses and deforms individually. Relatively high compression of one pad will not necessarily transfer compressive forces to its adjacent pad. In this way, uniform contact pressure is maintained at the nozzle face is cleaned more effectively. 
       Sinusoidal Blade 
       [0141]    In the wiping maintenance station  266  shown in  FIG. 41 , the single blade  314  is mounted into the hard plastic base  270  such that it follows a sinusoidal path. As previously discussed, wiping the nozzle face of pagewidth printhead with a single long contact surface can be ineffective. Inconsistent contact pressure between the wiping surface and the nozzle face can cause the contact pressure to be insufficient or non-existent in some areas. One of the reasons that the contact pressure will vary is inaccurate movement of the wiper surface relative to the nozzle face. If the support structure for the wiping surface is not completely parallel to the nozzle face over the entire length of travel during the wiping operation, there will be areas of low contact pressure which may not be properly cleaned. As explained in relation to the skew mounted blades, it is possible to avoid this by positioning the wiper blade so that it is angled relative to feed wiping direction and the printhead nozzle face. In this way, only one portion of the wiper blade contacts the nozzle face at any time during the wiping operation. Also, a small angle between the blade and the wiping direction improves the cleaning and effectiveness of the wipe. When the blade moves over the nozzle face at an incline, more contact points between the blade and the nozzle face give better contaminant removal. This ameliorates any problems caused by inconsistent contact pressure but it requires the wiper blade to travel further for each wiping operation. As discussed above, inaccuracies in the movement of wiper surface relative to the nozzle face is a source of insufficient contact pressure. Increasing the length of wiper travel is also counter to compact design. 
         [0142]    Using a wiping blade that has a zigzag or sinusoidal shape wipes the nozzle face with a number wiper sections that are inclined to the media feed direction. This configuration also keeps the length of travel of the wiper member relative to the printhead small enough to remain accurate and compact. 
         [0000]    Single Blade with Non-Linear Contact Surface 
         [0143]      FIG. 42  shows the wiping maintenance station  266  with a single blade  316  having two linear sections mounted on the hard plastic base  270  at an angle to each other, and skew to the wiping direction. As previously discussed, wiping the nozzle face of pagewidth printhead with a single long contact surface can cause the contact pressure to be insufficient or non-existent in some areas. Angling the blade relative to the wiping direction and the printhead nozzle face means that only one portion of the wiper blade contacts the nozzle face at any time during the wiping operation. This keeps the contact pressure more uniform but it requires the wiper blade to travel further for each wiping operation. As discussed above, inaccuracies in the movement of wiper surface relative to the nozzle face source of insufficient contact pressure. Increasing the length of wiper travel only increases the risk of such inaccuracies. 
         [0144]    By using a wiping surface that has an angled or curved shape so that the majority of the nozzle face is wiped with a wiper section that is inclined to the media feed direction while reducing the length of travel of the wiper member relative to the printhead. The ordinary worker will understand that the contact blade can have a shallow V-shape or U-shape. Furthermore if the leading edge of the blade  318  is the intersection of the two linear sections (or the curved section of the U-shaped blade), the Applicant has found that there is less blade wear because of the additional support provided to the initial point of contact with the nozzle face. 
       Fibrous Pad 
       [0145]      FIG. 45  shows a printhead wiper maintenance station  266  with a fibrous pad  320  mounted to the hard plastic base  270 . A fibrous pad  320  is particularly effective for wiping the nozzle face. The pad presents many points of contact with the nozzle face so that the fibres can mechanically engage with solid contaminants and will wick away liquid contaminants like ink floods and so on. However, once the fibrous pad has cleaned the nozzle face, it is difficult to remove the contaminants from the fibrous pad. After a large number of wiping operations, the fibrous pad can be heavily laden with contaminants and may no longer clean the nozzle face effectively. However, printers intended to have a short operational life, or printers that allow the wiper to be replaced, a fibrous pad will offer the most effective wiper. 
       Combination Wiper Maintenance Stations 
       [0146]    It will be appreciated that some printhead designs will be most effectively cleaned by a wiper that has a combination of the above wiping structures. For example a single blade in combination with a series of skew blades, or a series of parallel blades with a fibrous pad in between. The combination wiper maintenance station can be derived by choosing the specific wiping structures on the basis of their individual merits and strength. 
       Printhead Maintenance Facility Drive System 
       [0147]      FIGS. 47 to 50  show the media feed drive and the printhead maintenance drive in greater detail.  FIG. 48  shows the printhead maintenance carousel  150  and the drive systems in isolation. The maintenance carousel  150  is shown with the wiper blades  162  presented to the printhead (not shown). The perspective shown in  FIG. 48  reveals the paper exit guide  322  leading to the exit drive roller  178 . On the other side of the wiper blades  162  the main drive roller shaft  186  is shown extending from the main drive roller pulley  330 . This pulley is driven by the main drive roller belt  192  which engages the media feed motor  190 . The media feed drive belt  182  synchronises the rotation of the main drive roller  186  and the exit roller  178 . 
         [0148]    The exploded perspective in  FIG. 49  shows the individual components in greater detail. In particular, this perspective best illustrates the balanced carousel lift mechanism. The carousel lift drive shaft  160  extends between two identical carousel lift cams  172 . One end of the carousel lift shaft  160  is keyed to the carousel lift spur gear  174 . The spur gear  174  meshes with the worm gear  176  driven by the carousel lift motor  324 . The carousel lift rotation sensor  334  provides feedback to the print engine controller (not shown) which can determine the displacement of the carousel from the printhead by the angular displacement of the cams  172 . 
         [0149]    The carousel lift cams  172  contact respective carousel lift arms  158  via the cam engaging rollers  168  (it will be appreciated that the cam engaging rollers could equally be a surface of low friction material such as high density polyethylene-HDPE). As the cams  172  are identical and identically mounted to the carousel lift shaft  160  the displacement of the carousel lift arms  158  is likewise identical.  FIG. 47  is a section view taken along line  7 - 7  of  FIG. 2A  with the printhead cartridge  2  removed and the printhead maintenance carousel  150  also removed. This figure provides a clear view of the carousel lift spur gear  174 , its adjacent lift cam  172  and the corresponding carousel lift arm  158 . As the lift arms  158  are equidistant from the midpoint of the carousel  150 , the carousel lift drive is completely balanced and symmetrical when lifting and lowering the carousel. This serves to keep the various printhead maintenance stations parallel to the longitudinal extent of the printhead ICs. 
         [0150]    The carousel rotation drive is best illustrated in the enlarged exploded partial perspective of  FIG. 50 . The carousel rotation motor  326  is mounted to the side of the carousel lift structure  170 . The stepper motor sensor  328  provides feedback to the print engine controller (PEC) regarding the speed and rotation of the motor  326 . The carousel rotation motor  326  drives the idler gear  332  which in turn, drives the reduction gear (not shown) on the obscured side of the carousel lift structure  170 . The reduction gear meshes with the carousel spur gear  212  which is keyed to the carousel chassis for rotation therewith. 
         [0151]    As the carousel rotation and the carousel lift the controlled by a separate independent drives, each drive powered by a stepper motor that provides the PEC with with feedback as to motor speed and rotation, the printer has a broad range of maintenance procedures from which to choose. The carousel rotation motor  326  can be driven in either direction and at the variable speeds. Accordingly the nozzle face can be wiped in either direction and the wiper blades can be cleaned against the absorbent pad  152  in both directions. This is particularly useful if paper dust or other contaminants passed to the nozzle face because of a mechanical engagement with the surface irregularity on the nozzle face. Wiping in the opposite direction will often dislodge such mechanical engagements. It is also useful to reduce the speed of the wiper blades  162  as they come into contact with the nozzle face and then increase speed once the blades have disengaged the nozzle face. Indeed the wiper blades  162  can slow down for initial contact with the nozzle face and subsequently increase speed while wiping. 
         [0152]    Similarly, the wiper blades  162  can be moved past the doctor blade  154  at a greater speed than the blades are moved over the cleaning pad  152 . The blades  162  can be wiped in both directions with any number of revolutions in either direction. Furthermore the order in which the various maintenance stations are presented to the printhead can be easily programmed into the PEC and or left to the discretion of the user. 
         [0153]    The present invention has been described herein by way of example only. The ordinary worker will readily recognise many variations and modifications which do not depart from the spirit and scope of the broad inventive concept.