Patent Abstract:
A method of detecting an under actuation condition within a micro electro-mechanical device in the form of an ink ejection nozzle having an actuating arm that moves an ink displacing paddle when heat inducing electric current is passed through the actuating arm and having a movement sensor associated with the actuating arm. The method comprises the steps of passing at least one current pulse having a predetermined duration through the actuating arm and detecting for a predetermined level of movement of the actuating arm. A fault is detected to exist by comparing the detected movement with the movement for desired operation, and where a fault is present, at least one further current pulse having an energy level greater than the fault detecting pulse may be passed through the actuating arm in an attempt to clear the fault.

Full Description:
FIELD OF THE INVENTION  
         [0001]    This invention relates to a method of detecting and, if appropriate, remedying a fault in a micro electro-mechanical (MEM) device. The invention has application in ink ejection nozzles of the type that are fabricated by integrating the technologies applicable to micro electro-mechanical systems (MEMS) and complementary metal-oxide semiconductor (CMOS) integrated circuits, and the invention is hereinafter described in the context of that application. However, it will be understood that the invention does have broader application, to the remedying of faults within various types of MEM devices.  
         BACKGROUND OF THE INVENTION  
         [0002]    A high speed pagewidth inkjet printer has recently been developed by the present Applicant. This typically employs in the order of 51200 inkjet nozzles to print on A4 size paper to provide photographic quality image printing at 1600 dpi. In order to achieve this nozzle density, the nozzles are fabricated by integrating MEMS-CMOS technology.  
           [0003]    A difficulty that flows from the fabrication of such a printer is that there is no convenient way of ensuring that all nozzles that extend across the printhead or, indeed, that are located on a given chip will perform identically, and this problem is exacerbated when chips that are obtained from different wafers may need to be assembled into a given printhead. Also, having fabricated a complete printhead from a plurality of chips, it is difficult to determine the energy level required for actuating individual nozzles, to evaluate the continuing performance of a given nozzle and to detect for any fault in an individual nozzle.  
         SUMMARY OF THE INVENTION  
         [0004]    The present invention may be defined broadly as providing a method of detecting a fault within a micro electro-mechanical device of a type having a support structure, an actuating arm that is movable relative to the support structure under the influence of heat inducing current flow through the actuating arm and a movement sensor associated with the actuating arm. The method comprises the steps of:  
           [0005]    (a) passing at least one current pulse having a predetermined duration tp through the actuating arm, and  
           [0006]    (b) detecting for a predetermined level of movement of the actuating arm.  
           [0007]    The method as above defined permits in-service fault detection of the micro electro-mechanical (MEM) device. If the predetermined level of movement is not detected following passage of the current pulse of the predetermined duration through the arm, it might be assumed that movement of the arm is impeded, for example as a consequence of a fault having developed in the arm or as a consequence of an impediment blocking the movement of the arm.  
           [0008]    If it is concluded that a fault in the form of a blockage exists in the MEM device, an attempt may be made to clear the fault by passing at least one further current pulse (having a higher energy level) through the actuating arm.  
           [0009]    Thus, the present invention may be further defined as providing a method of detecting and remedying a fault within an MEM device. The two-stage method comprises the steps of:  
           [0010]    (a) detecting the fault in the manner as above defined, and  
           [0011]    (b) remedying the fault by passing at least one further current pulse through the actuating arm at an energy level greater than that of the fault detecting current pulse.  
           [0012]    If the remedying step fails to correct the fault, the MEM device may be taken out of service and/or be returned to a supplier for service.  
           [0013]    The fault detecting method may be effected by passing a single current pulse having a predetermined duration t p  through the actuating arm and detecting for a predetermined level of movement of the actuating arm. Alternatively, a series of current pulses of successively increasing duration t p  may be passed through the actuating arm in an attempt to induce successively increasing degrees of movement of the actuating arm over a time period t. Then, detection will be made for a predetermined level of movement of the actuating arm within a predetermined time window t w  where t&gt;t w &gt;t p .  
         PREFERRED FEATURES OF THE INVENTION  
         [0014]    The fault detection method of the invention preferably is employed in relation to an MEM device in the form of a liquid ejector and most preferably in the form of an ink ejection nozzle that is operable to eject an ink droplet upon actuation of the actuating arm. In this latter preferred form of the invention, the second end of the actuating arm preferably is coupled to an integrally formed paddle which is employed to displace ink from a chamber into which the actuating arm extends.  
           [0015]    The actuating arm most preferably is formed from two similarly shaped arm portions which are interconnected in interlapping relationship. In this embodiment of the invention, a first of the arm portions is connected to a current supply and is arranged in use to be heated by the current pulse or pulses having the duration t p . However, the second arm portion functions to restrain linear expansion of the actuating arm as a complete unit and heat induced elongation of the first arm portion causes bending to occur along the length of the actuating arm. Thus, the actuating arm is effectively caused to pivot with respect to the support structure with heating and cooling of the first portion of the actuating arm.  
           [0016]    The invention will be more fully understood from the following description of a preferred embodiment of a fault detecting method as applied to an inkjet nozzle as illustrated in the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    In the drawings:— 
         [0018]    [0018]FIG. 1 shows a highly magnified cross-sectional elevation view of a portion of the inkjet nozzle,  
         [0019]    [0019]FIG. 2 shows a plan view of the inkjet nozzle of FIG. 1,  
         [0020]    [0020]FIG. 3 shows a perspective view of an outer portion of an actuating arm and an ink ejecting paddle or of the inkjet nozzle, the actuating arm and paddle being illustrated independently of other elements of the nozzle,  
         [0021]    [0021]FIG. 4 shows an arrangement similar to that of FIG. 3 but in respect of an inner portion of the actuating arm,  
         [0022]    [0022]FIG. 5 shows an arrangement similar to that of FIGS. 3 and 4 but in respect of the complete actuating arm incorporating the outer and inner portions shown in FIGS. 3 and 4,  
         [0023]    [0023]FIG. 6 shows a detailed portion of a movement sensor arrangement that is shown encircled in FIG. 5,  
         [0024]    [0024]FIG. 7 shows a sectional elevation view of the nozzle of FIG. 1 but prior to charging with ink,  
         [0025]    [0025]FIG. 8 shows a sectional elevation view of the nozzle of FIG. 7 but with the actuating arm and paddle actuated to a test position,  
         [0026]    [0026]FIG. 9 shows ink ejection from the nozzle when actuated under a fault clearing operation,  
         [0027]    [0027]FIG. 10 shows a blocked condition of the nozzle when the actuating arm and paddle are actuated to an extent that normally would be sufficient to eject ink from the nozzle,  
         [0028]    [0028]FIG. 11 shows a schematic representation of a portion of an electrical circuit that is embodied within the nozzle,  
         [0029]    [0029]FIG. 12 shows an excitation-time diagram applicable to normal (ink ejecting) actuation of the nozzle actuating arm,  
         [0030]    [0030]FIG. 13 shows an excitation-time diagram applicable to test actuation of the nozzle actuating arm,  
         [0031]    [0031]FIG. 14 shows comparative displacement-time curves applicable to the excitation-time diagrams shown in FIGS. 12 and 13,  
         [0032]    [0032]FIG. 15 shows an excitation-time diagram applicable to a fault detection procedure,  
         [0033]    [0033]FIG. 16 shows a temperature-time diagram that is applicable to the nozzle actuating arm and which corresponds with the excitation-time diagram of FIG. 15, and  
         [0034]    [0034]FIG. 17 shows a deflection-time diagram that is applicable to the nozzle actuating arm and which corresponds with the excitation/heating-time diagrams of FIGS. 15 and 16. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0035]    As illustrated with approximately 3000× magnification in FIG. 1 and other relevant drawing figures, a single inkjet nozzle device is shown as a portion of a chip that is fabricated by integrating MEMS and CMOS technologies. The complete nozzle device includes a support structure having a silicon substrate  20 , a metal oxide semiconductor layer  21 , a passivation layer  22 , and a non-corrosive dielectric coating/chamber-defining layer  23 .  
         [0036]    The nozzle device incorporates an ink chamber  24  which is connected to a source (not shown) of ink and, located above the chamber, a nozzle chamber  25 . A nozzle opening  26  is provided in the chamber-defining layer  23  to permit displacement of ink droplets toward paper or other medium (not shown) onto which ink is to be deposited. A paddle  27  is located between the two chambers  24  and  25  and, when in its quiescent position, as indicated in FIGS. 1 and 7, the paddle  27  effectively divides the two chambers  24  and  25 .  
         [0037]    The paddle  27  is coupled to an actuating arm  28  by a paddle extension  29  and a bridging portion  30  of the dielectric coating  23 .  
         [0038]    The actuating arm  28  is formed (i.e. deposited during fabrication of the device) to be pivotable with respect to the support structure or substrate  20 . That is, the actuating arm has a first end that is coupled to the support structure and a second end  38  that is movable outwardly with respect to the support structure. The actuating arm  28  comprises outer and inner arm portions  31  and  32 . The outer arm portion  31  is illustrated in detail and in isolation from other components of the nozzle device in the perspective view shown in FIG. 3. The inner arm portion  32  is illustrated in a similar way in FIG. 4. The complete actuating arm  28  is illustrated in perspective in FIG. 5, as well as in FIGS. 1, 7,  8 ,  9  and  10 .  
         [0039]    The inner portion  32  of the actuating arm  28  is formed from a titanium-aluminium-nitride (TiAl)N deposit during formation of the nozzle device and it is connected electrically to a current source  33 , as illustrated schematically in FIG. 11, within the CMOS structure. The electrical connection is made to end terminals  34  and  35 , and application of a pulsed excitation (drive) voltage to the terminals results in pulsed current flow through the inner portion only of the actuating arm  28 . The current flow causes rapid resistance heating within the inner portion  32  of the actuating arm and consequential momentary elongation of that portion of the arm.  
         [0040]    The outer arm portion  31  of the actuating arm  28  is mechanically coupled to but electrically isolated from the inner arm portion  32  by posts  36 . No current-induced heating occurs within the outer arm portion  31  and, as a consequence, voltage induced current flow through the inner arm portion  32  causes momentary bending of the complete actuating arm  28  in the manner indicated in FIGS. 8, 9 and  10  of the drawings. This bending of the actuating arm  28  is equivalent to pivotal movement of the arm with respect to the substrate  20  and it results in displacement of the paddle  27  within the chambers  24  and  25 .  
         [0041]    An integrated movement sensor is provided within the device in order to determine the degree or rate of pivotal movement of the actuating arm  28  and in order to permit fault detection in the device.  
         [0042]    The movement sensor comprises a moving contact element  37  that is formed integrally with the inner portion  32  of the actuating arm  28  and which is electrically active when current is passing through the inner portion of the actuating arm. The moving contact element  37  is positioned adjacent the second end  38  of the actuating arm and, thus, with a voltage V applied to the end terminals  34  and  35 , the moving contact element will be at a potential of approximately V/2. The movement sensor also comprises a fixed contact element  39  which is formed integrally with the CMOS layer  22  and which is positioned to be contacted by the moving contact element  37  when the actuating arm  28  pivots upwardly to a predetermined extent. The fixed contact element is connected electrically to amplifier elements  40  and to a microprocessor arrangement  41 , both of which are shown in FIG. 11 and the component elements of which are embodied within the CMOS layer  22  of the device.  
         [0043]    When the actuator arm  28  and, hence, the paddle  27  are in the quiescent position, as shown in FIGS. 1 and 7, no contact is made between the moving and fixed contact elements  37  and  39 . At the other extreme, when excess movement of the actuator arm and the paddle occurs, as indicated in FIGS. 8 and 9, contact is made between the moving and fixed contact elements  37  and  39 . When the actuator arm  28  and the paddle  27  are actuated to a normal extent sufficient to expel ink from the nozzle, no contact is made between the moving and fixed contact elements. That is, with normal ejection of the ink from the chamber  25 , the actuator arm  28  and the paddle  27  are moved to a position partway between the positions that are illustrated in FIGS. 7 and 8. This (intermediate) position is indicated in FIG. 10, although as a consequence of a blocked nozzle rather than during normal ejection of ink from the nozzle.  
         [0044]    [0044]FIG. 12 shows an excitation-time diagram that is applicable to effecting actuation of the actuator arm  28  and the paddle  27  from a quiescent to a lower-than-normal ink ejecting position. The displacement of the paddle  27  resulting from the excitation of FIG. 12 is indicated by the lower graph  42  in FIG. 14, and it can be seen that the maximum extent of displacement is less than the optimum level that is shown by the displacement line  43 .  
         [0045]    [0045]FIG. 13 shows an expanded excitation-time diagram that is applicable to effecting actuation of the actuator arm  28  and the paddle  27  to an excessive extent, such as is indicated in FIGS. 8 and 9. The displacement of the paddle  27  resulting from the excitation of FIG. 13 is indicated by the upper graph  44  in FIG. 14, from which it can be seen that the maximum displacement level is greater than the optimum level indicated by the displacement line  43 .  
         [0046]    [0046]FIGS. 15, 16 and  17  shows plots of excitation voltage, actuator arm temperature and paddle deflection against time for successively increasing durations of excitation applied to the actuating arm  28 . These plots have relevance to fault detection in the nozzle device.  
         [0047]    When detecting for a fault condition in the nozzle device or in each device in an array of the nozzle devices, a series of current pulses of successively increasing duration t p  are induced to flow that the actuating arm  28  over a time period t. The duration t p  is controlled to increase in the manner indicated graphically in FIG. 15.  
         [0048]    Each current pulse induces momentary heating in the actuating arm and a consequential temperature rise, followed by a temperature drop on expiration of the pulse duration. As indicated in FIG. 16, the temperature rises to successively higher levels with the increasing pulse durations as shown in FIG. 15.  
         [0049]    As a result, as indicated in FIG. 17, under normal circumstances the actuator arm  28  will move (i.e. pivot) to successively increasing degrees, some of which will be below that required to cause contact to be made between the moving and fixed contact elements  37  and  39  and others of which will be above that required to cause contact to be made between the moving and fixed contact elements. This is indicated by the “test level” line shown in FIG. 17. However, if a blockage occurs in a nozzle device, as indicated in FIG. 10, the paddle  27  and, as a consequence, the actuator arm  28  will be restrained from moving to the normal full extent that would be required to eject ink from the nozzle. As a consequence, the normal full actuator arm movement will not occur and contact will not be made between the moving and fixed contact elements  37  and  39 .  
         [0050]    If such contact is not made with passage of current pulses of the predetermined duration t p  through the actuating arm, it might be concluded that a blockage has occurred within the nozzle device. This might then be remedied by passing a further current pulse through the actuating arm  28 , with the further pulse having an energy level significantly greater than that which would normally be passed through the actuating arm. If this serves to remove the blockage ink ejection as indicated in FIG. 9 will occur.  
         [0051]    As an alternative, more simple, procedure toward fault detection, a single current pulse as indicated in FIG. 12 may be induced to flow through the actuator arm and detection be made simply for sufficient movement of the actuating arm to cause contact to be made between the fixed and moving contact elements.  
         [0052]    Variations and modifications may be made in respect of the device as described above as a preferred embodiment of the invention without departing from the scope of the appended claims.

Technology Classification (CPC): 1