Abstract:
An inkjet printer with a printhead and a conduit connected to the printhead. The conduit defines a flow path for the printing fluid and has an internal cross section configured such that the surface tension of printing fluid within it favors gas bubble growth along the conduit length over radial bubble growth that would fully occlude the flow path.

Description:
FIELD OF THE INVENTION 
     The present invention relates to inkjet printers and in particular, the fluidic system for supplying the printhead with ink. 
     CROSS REFERENCES TO RELATED APPLICATIONS 
     Various methods, systems and apparatus relating to the present invention are disclosed in the following US patents/patent applications filed by the applicant or assignee of the present invention: 
     
       
         
               
               
               
               
               
               
               
             
           
               
                   
               
             
             
               
                 6,276,850 
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                 11/829,960 
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                 11/829,969 
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                 11/524,908 
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                 09/575,197 
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                 7,330,974 
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                 7,102,772 
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                 6,963,845 
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                 09/575,181 
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                 10/291,471 
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                 10/291,481 
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                 7,031,010 
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                 10/291,592 
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                 6,987,581 
               
               
                 7,216,224 
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                 7,293,234 
               
               
                 6,850,931 
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                 7,159,784 
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                 11/202,253 
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                 11/227,239 
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                 11/442,428 
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                 11/706,964 
                 11/739,032 
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                 11/839,542 
               
               
                 11/866,394 
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                 7,100,834 
               
               
                 7,270,396 
                 7,187,086 
                 7,290,856 
                 7,032,825 
                 7,086,721 
                 7,159,968 
                 7,010,456 
               
               
                 7,147,307 
                 7,111,925 
                 11/144,812 
                 7,229,154 
                 11/505,849 
                 11/520,570 
                 7,328,994 
               
               
                 7,341,672 
                 11/540,575 
                 11/583,937 
                 7,278,711 
                 7,290,720 
                 7,314,266 
                 11/635,489 
               
               
                 11/604,319 
                 11/635,490 
                 11/635,525 
                 7,287,706 
                 11/706,366 
                 11/706,310 
                 11/706,308 
               
               
                 11/785,108 
                 11/744,214 
                 11,744,218 
                 11,748,485 
                 11/748,490 
                 11/764,778 
                 11/766,025 
               
               
                 11/834,635 
                 11,839,541 
                 11,860,420 
                 11/865,693 
                 11/863,118 
                 11/866,307 
                 11/866,340 
               
               
                 11/869,684 
                 11/869,722 
                 11/869,694 
                 11/876,592 
                 11/945,244 
                 11,951,121 
                 11/945,238 
               
               
                 11,955,358 
                 11,965,710 
                 11,962,050 
                 12,015,478 
                 12,015,423 
                 12,015,434 
                 12,023,015 
               
               
                 12,030,755 
                 12,025,641 
                 12,036,279 
                 12,031,598 
               
               
                   
               
             
          
         
       
     
     BACKGROUND OF THE INVENTION 
     The Applicant has developed a wide range of printers that employ pagewidth printheads instead of traditional reciprocating printhead designs. 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 full colour 1600 dpi printing at speeds in the vicinity of 60 pages per minute; speeds previously unattainable with conventional inkjet printers. 
     Printing at these speeds consumes ink quickly and this gives rise to problems with supplying the printhead with enough ink. 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. 
     The ink conduits can be blocked by air bubbles. Air bubbles can form in the ink conduits when dissolved gasses come out of solution during periods of inactivity. If the bubble is big enough, it can completely occlude the conduit and block the ink flow. The bubble can pin to the inside of the conduit such that it requires a finite force to be applied to move it, as if it had a static coefficient of friction. The bubble resists moving with the ink flow and can starve areas downstream of the bubble, or cause a detrimental pressure increase upstream of the bubble. 
     SUMMARY OF THE INVENTION 
     According to a first aspect, the present invention provides an inkjet printer comprising: 
     a printhead with an array of nozzles for ejecting printing fluid; 
     a conduit connected to the printhead, the conduit defining a flow path for the printing fluid; wherein, 
     the conduit has an internal cross section configured such that the surface tension of the printing fluid favors gas bubble growth along the conduit length over radial bubble growth that fully occludes the flow path. 
     The invention is predicated on the realization that the inherent tendency for surface tension to adopt the lowest energy configuration can be used make gas bubbles grow longitudinally in the ink line instead of radially. By preventing the bubble from growing across the entire flow path, it may constrict the flow but not form a blockage. Ink can still flow through the line without first having to overcome the resistance of a bubble surface tension pinned to the internal surface. Importantly, this allows the pressure on either side of the bubble to equalize during printer standby periods. A pressure build up in the printhead because of diurnal temperature changes can flood the nozzles. 
     Preferably the internal cross section has a first area and the second area adjoining the first area, the first area being defined as an area that will allow radial growth of the gas bubble until it is completely occluded, and second area being defined as an area that will resist radial intrusion of a gas bubble that completely occludes the first area. Preferably, the second area is shaped such that any gas bubble capable of expanding radially from the first area into the second area until the second area is void of printing fluid, would require an internal gas pressure greater than the internal gas pressure of gas bubbles formed in the printing fluid by outgassing. 
     Preferably, the internal cross section is star-shaped. Preferably, the internal cross section is triangular. Preferably, the internal cross section is ‘T’-shaped. Preferably, the internal cross section is cross-shaped. Preferably, the internal cross section is ‘three leaf clover’-shaped. In another preferred form, the internal cross section is “four leaf clover”-shaped. 
     According to a second aspect, the present invention provides an inkjet printer comprising: 
     a printhead with an array of nozzles for ejecting printing fluid; 
     a conduit connected to the printhead, the conduit defining a flow path for the printing fluid; wherein, 
     the conduit has an internal cross section configured such that its dimension in a first direction far exceeds its dimension in the second direction normal to the first direction such that the gas bubble growing within the conduit will break into smaller separate gas bubbles before the fluid includes the flow path because of Plateau-Rayleigh instability. 
     This aspect of the invention recognises that the phenomenon known as Plateau-Rayleigh instability (named after Joseph Plateau and Lord Rayleigh who investigated the phenomenon in 1873) can be used to ensure that a single gas bubble is not completely occlude the flow path defined by a conduit. 
     Preferably, the cross section of the conduit is an elongate rectangle. Optionally, the cross section of the printhead can have several intersecting, elongate rectangle sections. In another preferred form, the cross section of the conduit is annular such that the radial width of the conduit is far less than the circumference. 
     In a particularly preferred form, the printing fluid reservoir is a sump positioned at a lower elevation than the printhead, the sump having a headspace of air above the printing fluid, and an inlet located in the headspace, the conduit being connected to the inlet such that during printer standby periods, the printing fluid in the conduit hanging from the printhead creates negative hydrostatic pressure in the printhead. 
     The high print speeds require a large ink supply flow rate. This mass of ink is moving relatively quickly through the supply line. Abruptly ending a print job, or simply at the end of a printed page, means that this relatively high volume of ink that is flowing relatively quickly must also come to an immediate stop. However, suddenly arresting the ink momentum gives rise to a pressure pulse in the ink line. The components making up the printhead are typically stiff and provide almost no flex as the column of ink in the line is brought to rest. Without any compliance in the ink line, the pressure spike can exceed the Laplace pressure (the pressure provided by the surface tension of the ink at the nozzles openings to retain ink in the nozzle chambers) and flood the front surface of the printhead nozzles. If the nozzles flood, ink may not eject and artifacts appear in the printing. 
     The Applicant has addressed these issues by incorporating non-priming cavities into the printhead. A detailed description of the non-priming cavities is provided in the Applicant&#39;s co-pending U.S. Ser. No. 11/688,863, the contents of which is incorporated herein by reference. Briefly, the stiff structures that define the ink line have air pockets distributed long the length of the printhead. A pressure pulse in the ink will compress the air in the cavity as it passes that point in the ink line. Compressing the air in the cavity damps and dissipates the pressure pulse to avoid nozzle flooding. 
     During standby periods when the printer is not operating for an extended time, temperature variations cause the air in the non-priming cavities to expand and contract. The ‘hanging’ column of ink in the downstream line to the sump keeps the printhead at a negative pressure so air expansion does not cause ink to flood from the nozzles. However, a bubble occlusion in the downstream ink line can create a blockage strong enough to prevent the hanging column of ink from accommodating the air expansion during diurnal temperature variations. Instead, the expanding air pockets pump ink out of the nozzles. The resulting flood on the nozzle face can cause color mixing and must be rectified before printing can commence. 
     Using a conduit according to the present invention, prevents any outgassing bubbles from completely occluding the ink flow path. As the outgassing bubbles do not form a flow obstruction, there is no build up pressure on the upstream side of bubble. Any expansion of the air in the air pockets pumps ink into the sump instead of causing a nozzle flood. Furthermore, the hanging column of ink maintains the correct negative pressure at the nozzles. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example only with reference to the preferred embodiments shown in the accompanying drawings, in which: 
         FIG. 1  is a schematic diagram of a printer fluidic system; 
         FIGS. 2A and 2B  are schematic transverse and longitudinal cross sections of a conduit during bubble nucleation; 
         FIGS. 3A and 3B  are schematic transverse and longitudinal cross sections of the conduit showing maximum radial bubble growth; 
         FIG. 4  is a sketch of a star-shaped cross section conduit; 
         FIG. 5  is a sketch of a triangular cross section conduit; 
         FIG. 6  is a sketch of a T-shaped cross section conduit; 
         FIG. 7  is a sketch of a ‘three leaf clover’ cross section conduit; 
         FIG. 8  is a sketch of a ‘four leaf clover’ cross section conduit; 
         FIGS. 9A to 9C  are sketches of bubble growth within a conduit according to a second aspect of the invention; and, 
         FIG. 10  is another embodiment of a conduit according to a second aspect of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       FIG. 1  is a schematic view of a prior art fluidic system of the type used in the above referenced U.S. Ser. No. 11/688,863. The operation of the system and its individual components are described in detail in U.S. Ser. No. 11/872,719 the contents of which are incorporated herein by reference. 
     Briefly, the printer fluidic system has a printhead assembly  2  supplied with ink from an ink tank  4  via an upstream ink line  8  and waste ink is drained to a sump  18  via a downstream ink line  16 . The downstream ink line  16  has a shut off valve  14  which allows the fluidic system to purge the nozzles to correct colour mixing or recover clogged nozzles. 
     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 . 
     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 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. 
     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. 
     As discussed above, temperature variations cause the air in the non-priming cavities to expand and contract. This can be problematic during standby periods when the printer is not operating for an extended time. The ‘hanging’ column of ink in the downstream line  16  to the sump  18  keeps the printhead  2  at a negative pressure so air expansion does not cause ink to flood from the nozzles  30 . However, a bubble occlusion in the downstream ink line  16  can create a blockage strong enough to prevent the hanging column of ink from accommodating the air expansion during diurnal temperature variations. Instead, the expanding air pockets pump ink out of the nozzles. The resulting flood on the nozzle face can cause color mixing and must be rectified before printing can commence. 
     This can be rectified using a conduit according to the present invention of the downstream ink line  16 .  FIGS. 2A and 2B  are sketches of the transverse and longitudinal cross sections of the conduit  16 . The cross section of the conduit  16  has two areas—the first area  42  and a second area  44 . Both the first and second areas  42  and  44  defining a flow path for the ink  50 . Outgassing bubble  40  nucleates on the side of the first area  42  and expands radially and longitudinally. 
     In  FIGS. 3A and 3B , the outgassing bubble  40  has grown to completely occlude the first area  42 . However the second area  44  remains filled with ink  50 . The shape of the outgassing bubble  40  is defined by the radius R tube  of the first area  42  and the maximum possible radius R max  at the unconstrained face  46  of the bubble  40 . The unconstrained face  46  of the bubble  40  will naturally tend towards the lowest energy state. Accordingly the radius of curvature R max  of the unconstrained face  46  will be the maximum that the gas pressure within the bubble  40  will allow (which corresponds to the minimum surface area that the bubble face  46  can have at the gas pressure). With increasing gas pressure, the radius of the bubble face  46  reduces, and the surface area of the bubble face  46  increases. 
     In order for the bubble  40  to continue growing into the second area  44  and eventually occluding it, the gas pressure within the bubble  40  would need to be enough to form a semicircular bubble surface  48  having a critical radius of curvature R crit . Knowing the internal gas pressure of outgassing bubbles  40 , the first area  42  and the second area  44  can adjoin each other such a way that R max  of any bubble surface  46  formed during the expected range of ambient conditions is greater than R crit . This will prevent any bubble  40  nucleating is the first area  42  from continuing to grow radially into the second area  44 . Instead further bubble roof will be in the longitudinal direction of the first area  42  (see  FIG. 3B ). In this way the ink  50  always has a flow path around the bubble  40 . 
     The ordinary worker will appreciate that the second area  44  can also the configured such that an outgassing bubble  40  nucleating on its inner wall will never grow large enough to occlude the first area  42 . Furthermore, once the printer has come out of standby mode as strong flow of ink from the printhead assembly  2  (see  FIG. 1 ) to the sump  18  will clear the downstream ink line  16  of the outgassing bubbles  40 . 
       FIGS. 4 to 8  are sketches of possible cross sections of the conduit  16 .  FIG. 4  shows a star-shaped cross section with a central for defining the first area  42  while the points of the star provide a plurality of second areas  44 . An outgassing bubble  40  in the first area  42  will not continue to grow radially into the points  44 . Instead, further bubble growth will be longitudinal. In this embodiment, if the outgassing bubble  40  nucleates in one of the points  44  of the star, then bubble growth may extend further into that point than any of the others. However, the remainder of the points will provide a flow path for the ink  50 . 
     Similarly, the triangular cross section shown in  FIG. 5  will contain any outgassing bubbles  40  in a central area  42  while vertices  44  of the triangle remains filled with ink  50 . In figure six, the cross section is T-shaped. Bubble  40  growth and occlusion in one section  42  of the ‘T’ will not extend into the other section  44  of the ‘T’. 
       FIGS. 7 and 8  show cross sections having a three leaf and four leaf clover shape respectively. These cross sections are particularly useful when applied to extruded, flexible tubing. Not only do the leafs  44  have a relatively large surface area to provide little resistance to any flow of ink  50  when central bore  42  is occluded by a bubble  40 , but the clover shape is resistant to kinking in a way that blocks all fluid flow. 
       FIGS. 9A ,  9 B and  9 C show the cross sections of conduit  16  according to the second aspect of the invention. These cross sections extend into one dimension X for more than the transverse dimension Y. If an outgassing bubble  40  nucleates in conduit  16  it will grow as a single bubble  40  in the X direction. However before the bubble  40  can extend completely across the conduit  16 , a phenomenon known as the Plateau Rayleigh instability will cause the bubble  40  to break up into separate bubbles  52 ,  54  and  56  (the  FIG. 9C ). This will ensure that the cross sections is never completely occluded and the ink  50  has flow path between an around the individual bubbles. 
     Optionally,  FIG. 10  shows the cross section of an annular conduit  16 . The circumference X of the annulus is far greater than the width Y of the annual flow path. Once again, any single outgassing bubbles will eventually become unstable and split into individual bubbles  52 ,  54  and  56 . Between these bubbles, the ink  50  maintains a flow path. 
     The present invention has been described herein by way of example only. Skilled workers in this field will readily recognise many variations and modifications which do not depart from the spirit and scope of the broad inventive concept.