Patent Publication Number: US-6213598-B1

Title: Pressure control device

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims the priority benefit of Taiwan application serial no. 87116229, filed Sep. 30, 1998, the full disclosure of which is incorporated herein by reference. 
     BACKGROUND OF THE INVENTION 
     1. Field of Invention 
     The present invention relates to a pressure control device. More particularly, the present invention relates to a pressure control device for controlling the pressure within the ink reservoir of an ink-jet pen. 
     2. Description of Related Art 
     Conventional ink-jet printing generally relies on the controlled delivery of ink droplets from an ink-jet pen ink reservoir to a print medium. Among the printing methods for delivering ink drops from the ink reservoir to the print head, drop-on-demand printing is known as the commonly used method. Drop-on-demand method typically uses thermal bubble or piezoelectric pressure wave mechanisms. A thermal bubble type print head includes a thin film resistor that is heated to cause sudden vaporization of a small portion of ink. The vapid expansion of the ink vapor forces a small drop of ink through a print head nozzle. 
     Although drop-on-demand printing is ideal for sending ink drops from an ink reservoir to the print head, some mechanism must be included to prevent ink leaking out from the print head when the print head is inactive. Such a mechanism usually can build a slight back pressure at the print head to prevent ink leakage from the pen whenever the print head is inactive. Herein, the term “back pressure” represents the partial vacuum within the ink reservoir. Back pressure is defined in the positive sense so that an increase in back pressure means the degree of partial vacuum has increased. 
     When back pressure is established at all times inside the reservoir, ink is prevented from permeating through the print head. However, the back pressure can not be so high that the print head is unable to overcome the back pressure to eject ink drops. Furthermore, as ambient air pressure decreases, a corresponding greater amount of back pressure is needed to keep ink from leaking. Accordingly, back pressure within the ink-jet pen has to be regulated whenever ambient pressure drops. Also the pressure within the pen is subjected to what may be termed “operational effects”. It is because the depletion of ink from the ink reservoir increases the reservoir back pressure. Without regulation of this back pressure increase, the ink-jet pen will fail soon because the back pressure is too high that the print head can not overcome it to eject ink drops. 
     Conventionally, the back pressure within the ink reservoir is controlled by a mechanism referred to as accumulators. In general, an accumulator includes an elastomeric bag capable of moving between a minimum volume position and a maximum volume position is response to changes in the back pressure within the ink reservoir. For example, as ambient pressure drops so that back pressure within the reservoir decreases simultaneously, the accumulator will move to increase the reservoir volume to thereby increase the back pressure to a level that prevent ink leakage. Another example is the depletion occurring during operation of the pen. In such a case, accumulators will move to decrease the reservoir volume to reduce the back pressure to a level within the operation range, thereby permitting the print head to continue ejecting ink. 
     However, although the accumulators such as elastomeric bags can adjust automatically the reservoir volume to keep the back pressure within the operation range, the extent to which elastomeric bags are capable of expanding is quite limited. Consequently, when ink gradually drops from the print head, the bag may reach its maximum extent and therefore incapable of any further adjustment of the reservoir volume. Hence, back pressure within the reservoir may increase such that ink droplets are prevented from coming out of the print head. 
     To resolve the aforementioned problems, some ink-jet pens employ a device called a “bubble generator”. The bubble generator has an orifice through which ambient air can enter the reservoir. The dimension of the orifice is such that ink is trapped within the orifice to seal off the reservoir by capillary effect. When ambient air pressure is high enough to overcome the liquid seal, air can bubble into the ink-jet reservoir. Therefore, back pressure within the reservoir can decrease and capillary effect will take over and re-establish the liquid seal again to prevent entrance of more air bubbles. 
     In general, bubble generators of ink-jet pens must satisfy a few conditions. Firstly, the bubble generator must be able to control back pressure precisely. Secondly, The range of fluctuation of the back pressure within the reservoir must be as small as possible. In other words, as air bubbles enter the reservoir leading to a drop of back pressure, the bubble generator must be able to stop the entrance of bubbles soon enough so that a suitable back pressure remains inside. Thirdly, the bubble generator must have self-wetting capability. The liquid seal must be able to prevent the entrance of bubbles even when most of the ink within the reservoir is used up, or alternately when the ink-jet pen is tilted so much that the bubble generator is no longer immersed below the ink. 
     FIG. 1 is a cross-sectional diagram showing a conventional design of the bubble generator according to U.S. Pat. No. 5,526,030. The bubble generator installed within the reservoir  102  has an orifice  104  and a sphere  106 . FIG. 2 is top view showing the surrounding structure of the bubble generator. As show in FIG. 2, the internal sidewalls of the orifice  104  contains equidistantly spaced protruding ribs  108  for centering the sphere  106 . The circular gap  110  between the sphere  106  and the orifice  104  is location where ambient bubbles are produced. 
     Normally, a bubble generator such as above is able to meet the demands required for printing with an ink-jet pen. In general, the entrance of bubbles into the ink-jet pen  102  is determined by surface tension of the ink itself, static pressure of the ink column and the gap  110  between the sphere  106  and the orifice  104 . Usually, the greater the surface tension of the ink or smaller the gap between the sphere and the orifice, the higher will be the back pressure required within the reservoir before air bubbles will start to enter. In addition, static pressure of the ink column within the reservoir can affect the value of back pressure required before air bubbles begin to enter the reservoir. Therefore, as ink gradually drops, static pressure of the ink column will decrease leading to the entrance of air bubbles at a smaller back pressure. In summary, major drawbacks of the aforementioned pressure control technique includes: 
     1. The value of back pressure within the ink-jet reservoir before bubble generator starts to function is related to surface tension of the ink used. Since various ink may have different surface tension, the minimum back pressure under which air bubbles can enter the reservoir may be different for each type of ink. Consequently, the gap between the sphere and the orifice must be designed for various ink. 
     2. The value of back pressure within the reservoir before bubble generator starts to function is also related to the static pressure generator by the column of ink. As ink within the reservoir drops gradually, static pressure acting on the bubble generator will drop making it easier for air bubbles to enter the reservoir. Often this will lead to a lowering of back pressure within the reservoir, and the adjustable range of the accumulator will be reduced. 
     3. The gap between the sphere and the orifice has to be precisely engineered to permit the entrance of air bubbles at the correct back pressure within the reservoir. This will increase difficulties in fabricating the reservoir of an ink-jet pen. 
     In light of the foregoing, there is a need to provide a better pressure control device within an ink-jet reservoir. 
     SUMMARY OF THIS INVENTION 
     Accordingly, the present invention is to provide a pressure control device capable of restricting the variation of back pressure within the ink-jet reservoir due to a dropping ink level through normal printing operation. 
     In another aspect, this invention provides a pressure control device whose controlling mechanism is independent of the ink used in the reservoir. In other words, back pressure within the reservoir is unaffected by the type of ink used. 
     To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention provides a pressure accumulator. The pressure control device is capable of adjusting back pressure within the reservoir, comprising a pressure plate; an expandable bag with one side attached to a first interior sidewall of the sealed reservoir and the other side attached to one side of the pressure plate, wherein the expandable bag further includes a short venting pipe passing through the sealed reservoir for communicating with air outside; and a spring device with one end attached to the other side of the pressure plate while the other end of the spring is attached to a second interior sidewall on the opposite side of the first interior sidewall of the sealed reservoir. 
     Another variation pressure accumulator within a sealed reservoir is provided, comprising a first and a second pressure plates; a first expandable bag with one side attached to a first interior sidewall of the sealed reservoir and the other side attached to one side of the first pressure plate, and a second expandable bag with one side attached to a second interior sidewall of the sealed reservoir and the other side attached to one side of the second pressure plate; and a spring device with one end attached to the other side of the first and the second pressure plates. 
     To achieve these and other advantages and in accordance with the purpose of the invention, as embodied and broadly described herein, the invention provides a pressure control device. The pressure control device is capable of adjusting back pressure within the reservoir similar to a bubble generator. The device is installed at the bottom of the reservoir. The device has an orifice whose upper end has an arc surface and that a sphere sits on the arc surface. Ideally, the sphere makes a line contact with the arc surface of the orifice. The device also has a flat spring with one end riveted onto the bottom of the reservoir. The flat spring has two portions: the first portion of the flat spring presses tightly against the sphere while the second portion touches a pressure plate within the reservoir. The reservoir further contains an expandable bag. When the bag within the reservoir expands, the pressure plate will push the second portion of the flat spring forward such that its first section will move away from the sphere. Due to the presence of a back pressure inside the reservoir, the sphere will be afloat briefly permitting ambient air to enter the reservoir through the orifice. 
     As soon as ambient air enters the reservoir, back pressure within the ink-jet reservoir will drop. Therefore, the bag within the reservoir will start to contract with the assistance of a spring. Very soon, force on the pressure plate that pushes against the second portion of the flat spring will be removed, and the flat spring will return to its former position. In other words, the first portion of the flat spring is once more pressing tightly against the sphere, and air bubbles can no longer enter the reservoir through the orifice. 
     Using the pressure control device of this invention, even when most of the ink is used, a back pressure within the reservoir can still maintain within a desirable level. 
     It is to be understood that both the foregoing general description and the following detailed description are exemplary, and are intended to provide further explanation of the invention as claimed. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The Accompanying drawings are included to provide a further understanding of the invention, and are incorporated in and constitute a part of this specification. The drawings illustrate embodiments of the invention and, together with the description, serve to explain the principles of the invention. In the drawings, 
     FIG. 1 is a cross-sectional diagram showing a conventional in-jet reservoir having a bubble generator inside; 
     FIG. 2 is a top view of the bubble generator illustrated in FIG. 1; 
     FIGS. 3A and 3B are cross-sectional views showing the components inside an ink-jet pen including an expandable bag in the expanded/contracted position according to the embodiment of this invention; 
     FIGS. 4A and 4B are cross-sectional views showing the components inside an ink-jet pen including an expandable bag in the expanded/contracted position according to another embodiment of this invention; 
     FIG. 5 is a cross-sectional view showing a pressure control device according to this invention; 
     FIG. 6 is a cross-sectional view showing the components inside an ink-jet reservoir including an expandable bag in the contacted position according to the embodiment of this invention; 
     FIG. 7 is a cross-sectional view showing the components inside an ink-jet reservoir including an expandable bag in the expanded position according to the embodiment of this invention; 
     FIG. 8 is a cross-sectional view showing the liquid seal established by the pressure control device of this invention; and 
     FIG. 9 is a graph comparing variation of back pressures versus the amount of ink (in cc) drained away from the ink-jet reservoir between a conventional controller and the pressure control device of this invention. 
    
    
     DESCRIPTION OF THE REFERRED EMBODIMENTS 
     Reference will now be made in detail to the present referred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. 
     EXAMPLE 1 
     FIGS. 3A and 3B are cross-sectional views showing the components inside an ink-jet pen including an expandable bag  416  in the contracted position to the embodiment of this invention. As show in FIG. 3A, the ink-jet pen  400  is actually a reservoir having rigid sidewalls  400   a ,  400   b ,  400   c  and a cap  405 . Inside the ink-jet pen  400 , there is an accumulator  410 . The accumulator  410  is in fact an assembly of components that includes a pressure plate  412 , a spring  414  and an expandable bag  416 . The bag  416  further includes a first chamber  416   a  and a second chamber  416   b . The first chamber  416   a  is connected to ambient air via a connecting pipe  418 . Consequently, ambient air is able to flow into and out of the bag  416 . The connecting pipe  418  passes through the cap  405  of the ink-jet pen with its end tightly sealed. Therefore, the only path for air into and out of the bag is through the connecting pipe  418 . Between the first chamber  416   a  and the second chamber  416   b , there is an opening  420  permitting the flow of air between the chambers. 
     One side of the bag  416  is in contact with the inner side wall  400   b  of the ink-jet pen  400  while the other side of the bag  416  is in contact with the first side  412   a  of the pressure plate  412 . The second side  412   b  of the pressure plate  412  is supported by one end of the spring  414  while the other end of the spring  414  is supported by the inner side wall  400   a  of the ink-jet pen  400 . 
     With the accumulator  410  in place, the reservoir is filled with ink through a sealable port  430 . After the ink-jet pen  400  is filled, a seal cap  432  is used to seal off the port  430  so that the ink-jet pen  400  is cut off from direct contact with the atmosphere. At this moment, a minimum back pressure is established within the pen reservoir. The minimum back pressure can prevent ink leaking through the print head  440  when the print head  440  is inactive. 
     When the ink-jet pen  400  is used for printing, the air pressure within the reservoir decreases as ink is depleted. Hence, the back pressure increases. During printing, the bag  416  will then expand as shown in FIG.  3 A. As the bag  416  expands, it will push on the pressure plate  412  and compress the spring  414  thereby reducing the volume of the reservoir to maintain the reservoir back pressure within a adequate level such that the print head  440  is able to continue ejecting ink from the reservoir. 
     When ambient air pressure decreases, for example, during air transportation of the pen, the spring  414  will push the pressure plate  412  against the bag  416  so that the bag  416  will contract due to a lower ambient pressure, as shown in FIG.  3 B. The contraction of the bag  416  will increase the volume of the pen reservoir so that the back pressure within the reservoir, relative to ambient, does not drop to a level that permits ink to leak from the print head  440 . 
     EXAMPLE 2 
     FIGS. 4A and 4B are cross-sectional views showing the components inside an ink-jet pen including a number of expandable bags (for example, two separate bags) in the expanded/contracted position to another embodiment of this invention. 
     As show in FIG. 4A, the ink-jet pen  500  is actually a reservoir having rigid sidewalls  500   a ,  500   b ,  500   c  and a cap  505 . Inside the ink-jet pen  500 , there is an accumulator  510 . The accumulator  510  is in fact an assembly of components that includes a number of pressure plates (for example, two plates  512   a ,  512   b ), a spring  514  and two expandable bags  516   a ,  516   b . The bags  516   a ,  516   b  are connected to ambient air via connecting pipes  518   a ,  518   b . Consequently, ambient air is able to flow into and out of the bag  516   a ,  516   b . The connecting pipes  518   a ,  518   b  passe through the cap  505  of the ink-jet pen  500  with its end tightly sealed. Therefore, the only path for air into and out of the bags  516   a ,  516   b  are through the connecting pipes  518   a ,  518   b.    
     As shown in FIG. 4A, one side of the bags  516   a ,  516   b  are respectively in contact with the inner sidewall  500   b  and  500   a  of the ink-jet pen  500  while the other side of the bags  516   a ,  516   b  are respectively in contact with the first side  520   a ,  522   a  of the pressure plates  512   a ,  512   b . The second side  520   b ,  522   b  of the pressure plates  512   a ,  512   b  is supported by ends of the spring  514 . 
     With the accumulator  510  in place, the reservoir is filled with ink through a sealable port  530 . After the ink-jet pen  500  is filled, a seal cap  532  is used to seal off the port  530  so that the ink-jet pen  500  is cut off from direct contact with the atmosphere. At this moment, a minimum back pressure is established within the pen reservoir  500 . The minimum back pressure can prevent ink leaking through the print head  540  when the print head  540  is inactive. 
     When the ink-jet pen  500  is used for printing, the air pressure within the reservoir decreases as ink is depleted. Hence, the back pressure increases. During printing, the bags  516   a ,  516   b  expand as shown in FIG.  4 A. As the bags  516   a ,  516   b  expand, they will push on the pressure plates  512   a ,  512   b , respectively and compress the spring  518  thereby reducing the volume of the reservoir to maintain the reservoir back pressure within a adequate level such that the print head  540  is able to continue ejecting ink from the reservoir. 
     When ambient air pressure decreases, for example, during air transportation of the pen, the spring  514  will push the pressure plates  512   a ,  512   b  against the bags  516   a ,  516   b  so that the bags  516   a ,  516   b  will contract due to a lower ambient pressure, as shown in FIG.  4 B. The contraction of the bag  516   a ,  516   b  increase the volume of the pen reservoir so that the back pressure within the reservoir, relative to ambient, does not drop to a level that permits ink to leak from the print head  540 . 
     EXAMPLE 3 
     FIG. 5 is a cross-sectional view showing a pressure control device according to this invention. The pressure control device is installed at the bottom part  400   c  of an ink-jet pen  400 . Position of the pressure control device includes a tubular boss  310  having an arc surface  312  at its upper end. A sphere  320  sits on top of the arc surface  312 . Ideally, the sphere  320  should form a line contact with the arc surface  312  of the boss  310 . A flat spring  330  is fixed by a rivet  332  to the bottom  400   c  of the ink-jet pen. The flat spring  330  includes a first portion  330   a  and a second portion  330   b . The first portion  330   a  of the flat spring  330  will press on the sphere  320  tightly while the second portion  330   b  is in contact with a pressure plate  412  next to it. In addition, there is an expandable bag  416  on one side of the ink-jet pens  400 . As the bag  416  expands, the pressure plate  412  will push the second portion  330   b  of the flat spring  330 , thus lifting the first portion  330   a  away from the sphere  320 . Due to back pressure inside the ink-jet pen, the back pressure overcomes the capillary forces of the ink and the sphere  320  will become afloat for a while because ambient air is bubbling into the reservoir to reduce the back pressure. 
     FIG. 6 is cross-sectional view showing the components inside an ink-jet pen including an expandable bag  416  in the contracted position to the embodiment of this invention. As show in FIG. 6, the ink-jet pen  400  is actually a reservoir having rigid sidewalls  400   a ,  400   b ,  400   c  and a cap  405 . Inside the ink-jet pen  400 , there is an accumulator  410 . The accumulator  410  is in fact an assembly of components that includes a pressure plate  412 , a spring  414  and an expandable bag  416 . The bag  416  further includes a first chamber  416   a  and a second chamber  416   b . The first chamber  416   a  is connected to ambient air via a connecting pipe  418 . Consequently, ambient air is able to flow into and out of the bag  416 . The connecting pipe  418  passes through the cap  405  of the ink-jet pen with its end tightly sealed. Therefore, the only path for air into and out of the bag is through the connecting pipe  418 . Between the first chamber  416   a  and the second chamber  416   b , there is an opening  420  permitting the flow of air between the chambers. 
     One side of the bag  416  is in contact with the inner side wall  400   b  of the ink-jet pen  400  while the other side of the bag  416  is in contact with the first side  412   a  of the pressure plate  412 . The second side  412   b  of the pressure plate  412  is supported by one end of the spring  414  while the other end of the spring  414  is supported by the inner side wall  400   a  of the ink-jet pen  400 . 
     With the accumulator  410  in place, the reservoir is filled with ink through a sealable port  430 . After the ink-jet pen  400  is filled, a seal cap  432  is used to seal off the port  430  so that the ink-jet pen  400  is cut off from direct contact with the atmosphere. At this moment, a minimum back pressure is established within the pen reservoir. The minimum back pressure can prevent ink leaking through the print head  440  when the print head  440  is inactive. 
     When the ink-jet pen  400  is used for printing, the air pressure within the reservoir decreases as ink is depleted. Hence, the back pressure increases. During printing, the bag  416  will then expand as shown in FIG.  6 . As the bag  416  expands, it will push on the pressure plate  412  and compress the spring  414  thereby reducing the volume of the reservoir to maintain the reservoir back pressure within a adequate level such that the print head  440  is able to continue ejecting ink from the reservoir. When ambient air pressure decreases, for example, during air transportation of the pen, the spring  414  will push the pressure plate  412  against the bag  416  so that the bag  416  will contract due to a lower ambient pressure. The contraction of the bag  416  will increase the volume of the pen reservoir so that the back pressure within the reservoir, relative to ambient, does not drop to a level that permits ink to leak from the print head  440 . 
     As the bag  416  expands to its largest possible expandable volume, reservoir volume can not change further. From this moment on, if the print head  440  continues to eject ink, back pressure within the reservoir will increase to a level that the print head  440  will no longer be able to overcome the back pressure such that the print head stop ejecting ink. Therefore, it is the object of the invention to provide device for regulating the pressure in an ink-jet pen that minimizes the amount of unusable ink which is discarded with an ink-jet pen that stops printing because the back pressure exceeded the operating range. 
     FIG. 7 is a cross-sectional view showing the components inside an ink-jet pen including an expandable bag in the expanded position according to the embodiment of this invention. As shown in FIG. 7, as bag  416  continues to expand (in direction B), the pressure plate  412  will be pushed sideways. The lower portion of the pressure plate  412  is in contact with the second portion  330   b  of the flat spring  330 . Due to compression by the pressure plate  412 , the first portion  330   a  of the flat spring  330  will be lifted up such that the first portion  330   a  and the sphere  320  are separated. When the flat spring  330  is no longer pressing on the sphere  320 , the back pressure within the reservoir will make the sphere  320  be uplifted briefly to create a gap between the tubular boss  310  and the sphere  320 . Consequently, the back pressure overcomes the capillary forces of the ink so that ambient air is bubbling into the reservoir to reduce the back pressure. 
     As ambient air is bubbled into the reservoir, the back pressure within the reservoir will decrease, thus the bag  416  will move sideways in the direction A due to the compression of the spring  414 . At this moment, the flat spring  330  is no longer pushed by the pressure plate  412 . Under its restorative force, the flat spring  330  moves back (as shown in FIG. 6) and the first portion  330   a  of the flat spring  330  is again pressing on the sphere  320  to seal off the boss  310 . Once the boss  310  is re-sealed, air can no longer enter the pen reservoir. 
     The ink-jet pen  400  will alternate between the configuration as shown in FIG.  7  and the one shown in FIG. 6 as ink continues to drop through paper printing operations. 
     In addition, liquid sealing and self-wetting capability are also provided by the pressure control device of this invention. FIG. 8 is cross-sectional view showing the liquid seal on the pressure control device of this invention. The space from the circular contact line (formed by the sphere  320  sitting on the boss  310 ) to the uppermost rim of the boss  310  can trap a quantity of ink due to the capillary of the ink. This pool of ink constitutes a liquid seal and having a self-wetting capability. 
     In summary, advantages of using the pressure control device of this invention to operate an ink-jet print head includes: 
     1. The pressure control device of this invention is able to provide a back pressure within the pen reservoir unaffected by surface tension of the type of ink used. Actual testing reveals that conventional pressure control device can have a variation of about 2 to 3 cm-WC within the ink-jet reservoir when different types of inks are used. 
     2. The pressure control device of this invention is capable of providing a back pressure within the ink-jet that varies within a smaller level as shown in FIG.  9 . Conventional device produces a back pressure (curve I) between 13 to 18 cm-WC, a variation of about 5 cm-WC. The device of this invention, however, is able to produce a back pressure (curve II) between 18 to 21 cm-WC, which is a variation of only 3 cm-WC. Hence, a better print quality is obtained because the variation of the back pressure that the print head has to overcome is minimized. 
     3. The pressure control device does not require precise control of gap dimension between the sphere and the tubular boss. Therefore, the back pressure at which air bubbles into the reservoir can be controlled precisely. 
     4. The pressure control device is constructed using simple components, which does not occupy much reservoir space. Moreover, the components are easy to manufacture and easy to assembly, therefore production cost is low. 
     It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.