Improved print head apparatus

Abstract: The present invention provides for a method manufacturing a print element assembly comprising an arm member (14) connecting a print element (12) to an electromagnetically driven armature (10) of a print head apparatus (6), characterized by the steps of forming said armature with at least one recess (40,42,44), locating said armature (10) in a mould cavity such that said at least one recess (40,42,44) communicates with said mould cavity, locating a portion of said print element (12) in said mould cavity, and applying molten material to said cavity so as to form said arm member (14), said molten material surrounding said portion and entering said at least one recess (40,42,44) whereby, upon solidification of said molted material, said print element (12) is secured to said arm member (14) and said arm member (14) is secured to said armature (10).

Description: The present invention relates to print head apparatus and a method of making the same, and in particular but not exclusively, to dot matrix print head apparatus and a method of making the same. Dot matrix type printers are widely used in various types of data processing and other systems, including retail point of sale terminals, financial terminals and other devices. Such printers have a print head including a print wire connected to an electromagnetically driven armature by way of an arm member and are versatile in being able to print a wide variety of type fonts and other characters and symbols and provide for simplicity and reliability of operation. Although such printers are relatively low in cost in comparison with other types of printers, such as laser printers, the arm member, which commonly comprises a stamped steel member, and its mode of connection to the armature and print wire, which commonly comprises riveting or brazing, provides a disadvantageously high proportion of construction costs. Thus, a reduction in the cost of forming an arm member connecting the print wire and armature would advantageously reduce the cost of such apparatus. JP-A-57 22 073 discloses a spring charge type printing hammer, having a main body and an armature section with an L shaped printing wire partially embedded therein. The armature section is made of a light and strong composite material, such as a plastic strengthened by carbon fibre. The L shaped printing wire is embedded into the armature section so that they become a continuous body, and the armature section and main body are either joined by an adhesive or formed as an integral body at the time of manufacture. The present invention seeks to provide a printhead apparatus in which the armature and print wire are connection in a more economical manner. In accordance with a first aspect of the present invention there is provided a method of manufacturing a print element assembly comprising an arm member connecting a print element to an electromagnetically driven armature of a print head apparatus, comprising the steps of forming said armature with at least one recess, locating said armature in a mould cavity such that said at least one recess communicates with said mould cavity, locating a portion of said print element in said mould cavity, and applying molten material to said cavity so as to form said arm member, said molten material surrounding said portion and entering said at least one recess whereby, upon solidification of said molten material, said print element is secured to said arm member and said arm member is secured to said armature. In accordance with a second aspect of the present invention there is provided a print head apparatus having a print element assembly comprising an armature to be driven in operation by electromagnetic means, and an arm member connecting a print element to said armature for movement therewith, wherein said armature has at least one recess, a first portion of said arm member is moulded into said at least one recess and a second portion of said arm member is moulded around a portion of said print element. It will be appreciated that the present invention provides a means for forming a secure connection between the print element and the armature in a simple moulding step, so that a significant reduction in manufacturing costs is achieved. It is a further advantage of the present invention that the arm member can be readily provided in a material having a low mass movement of inertia such that the speed at which the print head operates reliably is increased. The invention is described further hereinafter, by way of example only, with reference to the accompanying drawings in which: Fig. 1 is a part sectional elevational view of a print wire actuator including an arm rigidly connecting an armature and a print wire and embodying the present invention. Fig. 2 is a perspective view of the arm of Fig. 1 as separated from the armature. Fig. 3 is a perspective view similar to Fig. 2, but showing the armature and the arm in assembled relation. Fig. 4 is a sectional view of the armature, taken along line 4-4 of Fig. 2. Referring now to Fig. 1, an armature and print wire assembly 8 embodying the present invention is shown in relationship with other major parts of an actuator 6. The armature and print wire assembly 8 comprises an armature 10, a print wire 12 and an interconnecting arm 14 (Figs. 2, 3 and 4), which may be of plastic material and formed by injection molding, and which attaches the print wire 12 rigidly to the armature 10. The plastic arm 14 may have a portion 15 of reduced thickness. The print wire 12 is guided and supported by wire guides 16 and 18. The armature 10 coacts with an electromagnetic energizing device 20, which comprises an electromagnetic coil 22 and a magnetic core 24. In a cycle of operation, the coil 22 is energized, which generates magnetic flux in the working air gap 26. This generates force on the armature 10, causing the armature and print wire assembly 8 to rotate in a clockwise direction about a pivot location 28, on the armature 10, which cooperates with a fulcrum 30 in the actuator 6. The print wire 12 is driven toward an ink ribbon 32 and a record medium 34, to effect printing on said record medium. Parts are dimensioned so that at the time the tip of the print wire 12 contacts and compresses the ribbon 32 and the record medium 34, the air gap 26 is still not completely closed. Therefore the full kinetic energy of the rotating armature and print wire assembly 8 is available for producing a dot on the record medium 34. At this point, the coil 22 is turned off, and the armature and print wire assembly 8 rebounds from the record medium 34 and returns to the home position. A return spring 36 assists in the return motion and the subsequent settling out of the assembly 8 against a backstop damper 38. The armature and print wire assembly 8 is made by an insert molding operation in which the metal armature 10 and the metal print wire 12 are placed in the cavity of a mold (not shown). The mold is then closed and molten plastic is injected to form the arm 14. The armature design incorporates recessed portions 40 and 42, as well as slotted portion 44, that fill with plastic during molding, and lock the armature 10 securely to the plastic arm 14 after the plastic has solidified. The print wire 12 is designed with a bend 46 and a straight portion 48 that extends along and inside the arm 14 toward the armature 10. This portion adds to the strength and rigidity of the plastic arm 14 and securely locks the print wire 12 to the arm 14. It also provides a place to hold and locate the print wire 12 in proper position in the mold cavity during injection of the molten plastic. After the injected plastic material has hardened, the mold is opened and the armature and print wire assembly 8 is removed. Assemblies have been molded using a carbon fibre filled nylon 6/6 material which has mechanical properties advantageous for this application; i.e. high modules of elasticity, high strength, and good temperature and fatigue capability. The armature 10 has been made from 3 percent silicon iron by a metal injection molding process. This process can provide the intricate slots and recesses required by this part. The advantages of this armature and print wire design are firstly that a low cost means of attaching the print wire 12 to the armature 10 is provided, and additionally an assembly with a low mass moment of inertia about the pivot can be provided. Other methods of construction such as using a stamped steel arm require brazing the print wire to the arm and either brazing or riveting the armature to the arm. This is estimated to be a more costly process than the insert molding operation. Also the required rigidity and strength can be attained with a plastic arm design which has a lower mass moment of inertia than an assembly utilizing a steel arm. Minimizing the mass moment of inertia of the armature and print wire assembly minimizes the response time of the actuator. This is desirable in the design of a printhead actuator 6 which must operate at a high repetition rate. Actuators employing the armature and print wire assembly described in this disclosure have been found to operate well at frequencies in excess of 1800 hertz.

Claims: A method of manufacturing a print element assembly comprising an arm member (14) connecting a print element (12) to an electromagnetically driven armature (10) of a print head apparatus (6), comprising the steps of forming said armature (10) with at least one recess (40,42,44), locating said armature (10) in a mould cavity such that said at least one recess (40,42,44) communicates with said mould cavity, locating a portion (46,48) of said print element (12) in said mould cavity, and applying molten material to said cavity so as to form said arm member (14), said molten material surrounding said portion (46,48) and entering said at least one recess (40,42,44) whereby, upon solidification of said molten material, said print element (12) is secured to said arm member (14) and said arm member is secured to said armature (10). A method according to claim 1, characterized in that said molten material comprises a plastic material. A method according to claim 2, characterized in that said plastic material comprises a carbon fibre filled nylon 6/6 material. A method according to claim 1, 2 or 3, characterized in that said armature (10) is formed from 3% silicon iron. A method according to any of the preceding claims, characterized in that said arm member (14) is formed by way of an injection moulding process. A method according to any one of the preceding claims, characterized in that said print element (12) comprises a print wire which is bent to form said portion (46,48). Print head apparatus (6) having a print element assembly comprising an armature (10) to be driven in operation by electromagnetic means (22,24), and an arm member (14) connecting a print element (12) to said armature (10) for movement therewith, wherein said armature (10) has at least one recess (40,42,44), a first portion of said arm member (14) is moulded into said at least one recess (40,42,44) and a second portion of said arm member (14) is moulded around a portion of said print element (12). Print head apparatus according to claim 7, characterized by return spring means (36) to return said arm member (14) and said print element (12) to a non-actuated position after de-energization of said electromagnetic means. Print head apparatus according to claim 8, characterized by a damper member (38) for damping the return movement of said arm member (14) and said print element (12).

Inventors: WEEKS DAVID EDWIN, WIRTH ROBERT LOUIS, WEEKS, DAVID EDWIN, WIRTH, ROBERT LOUIS
Applicants: NCR INT INC, NCR INTERNATIONAL INC.
Application year: 1992
Main classification: B41J2
IPC codes: B41J2