U.S. patent application number 09/892203 was filed with the patent office on 2002-05-30 for gas extraction device for extracting gas from a microfluidics system.
Invention is credited to Barth, Phillip W., Donald, David K., Field, Leslie A., Hoen, Storrs T., Servaites, Jonathan.
Application Number | 20020062736 09/892203 |
Document ID | / |
Family ID | 22826031 |
Filed Date | 2002-05-30 |
United States Patent
Application |
20020062736 |
Kind Code |
A1 |
Field, Leslie A. ; et
al. |
May 30, 2002 |
GAS EXTRACTION DEVICE FOR EXTRACTING GAS FROM A MICROFLUIDICS
SYSTEM
Abstract
A thermally-activated gas extraction device that comprises a
bubble capture chamber, an exhaust manifold, a tapered extraction
chamber and an extraction heater associated with the tapered
extraction chamber. The tapered extraction chamber extends from the
bubble capture chamber towards the exhaust manifold and has a
cross-sectional area that increases towards the exhaust manifold. A
gas removal method in which the gas extraction device is provided,
a bubble of gas is accumulated in the bubble capture chamber, a
portion of the liquid in the tapered extraction chamber heated to
nucleate a bubble of vapor, and the bubble of vapor is heated to
explosively expand the bubble of vapor into contact with the walls
of the tapered extraction chamber and into contact with the bubble
of gas to form a composite bubble. Contact with the walls of the
tapered extraction moves the composite bubble towards the exhaust
manifold. Finally, heating of the composite bubble is discontinued
to condense the vapor in the composite bubble.
Inventors: |
Field, Leslie A.; (Portola
Valley, CA) ; Donald, David K.; (Mountain View,
CA) ; Barth, Phillip W.; (Portola Valley, CA)
; Servaites, Jonathan; (Anapolis, MD) ; Hoen,
Storrs T.; (Brisbane, CA) |
Correspondence
Address: |
HEWLETT-PACKARD COMPANY
Intellectual Property Administration
P.O. Box 272400
Fort Collins
CO
80527-2400
US
|
Family ID: |
22826031 |
Appl. No.: |
09/892203 |
Filed: |
June 25, 2001 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09892203 |
Jun 25, 2001 |
|
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|
09221026 |
Dec 23, 1998 |
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Current U.S.
Class: |
95/241 |
Current CPC
Class: |
B41J 2/19 20130101 |
Class at
Publication: |
95/241 |
International
Class: |
B01D 019/00 |
Claims
We claim:
1. A thermally-activated gas extraction device, comprising: a
bubble capture chamber; an exhaust manifold; a tapered extraction
chamber extending from the bubble capture chamber towards the
exhaust manifold, the tapered extraction chamber having a
cross-sectional area that increases towards the exhaust manifold;
and an extraction heater associated with the tapered extraction
chamber.
2. The thermally-activated gas extraction device of claim 1, in
which the tapered extraction chamber includes: a neck adjacent the
bubble capture chamber; and a tapered chamber extending from the
neck towards the exhaust manifold, the tapered chamber having a
cross-sectional area that increases with increasing distance from
the neck.
3. The thermally-activated gas extraction device of claim 2, in
which the tapered chamber includes a substantially semicircular
portion adjacent the exhaust manifold.
4. The thermally-activated gas extraction device of claim 1, in
which: the extraction heater is located in the tapered extraction
chamber; and the gas extraction device additionally comprises a
gas-release heater located in the bubble capture chamber.
5. The thermally-activated gas extraction device of claim 4, in
which the gas extraction device additionally comprises a fluid flow
channel, the fluid flow channel including a portion shaped to
define a region having a low spatial potential energy potential
bounded by at least one region of a higher spatial energy potential
as the bubble capture chamber.
6. The thermally-activated gas extraction device of claim 5, in
which: in the region having the low spatial energy potential, the
fluid flow channel has a first cross-sectional area; in the at
least one region of a higher spatial energy, the fluid flow channel
includes regions having a second cross-sectional area, smaller than
the first cross-sectional area, and located upstream and downstream
of the region having the low spatial energy potential.
7. The thermally-activated gas extraction device of claim 5, in
which the region of a higher spatial energy potential includes an
arrangement of pillars located in the fluid flow channel and
substantially surrounding the region of low spatial energy
potential.
8. The thermally-activated gas extraction device of claim 1, in
which: the gas extraction device additionally comprises: a
substrate, and a barrier layer adjacent the substrate; the exhaust
manifold extends through the substrate; and the bubble capture
chamber and the extraction chamber are defined in the barrier
layer.
9. The thermally-activated gas extraction device of claim 1, in
which: the tapered extraction chamber is a secondary extraction
chamber; and the gas extraction device additionally comprises a
primary extraction chamber interposed between the secondary
extraction chamber and the bubble capture chamber, the primary
extraction chamber having a cross-sectional area that increases
towards the exhaust manifold.
10. The thermally-activated gas extraction device of claim 9, in
which the secondary extraction chamber has a larger cross-sectional
area than the primary extraction chamber.
11. The thermally-activated gas extraction device of claim 1, in
which: the extraction heater is located in the bubble capture
chamber; the bubble capture chamber includes a boundary having a
spatial energy potential; the tapered extraction chamber includes a
mouth adjacent the bubble capture chamber; and the mouth of the
tapered extraction chamber has a spatial energy potential less than
the spatial energy potential of the boundary of the bubble capture
chamber.
12. The thermally-activated gas extraction device of claim 11, in
which the extraction heater additionally functions as a gas release
heater.
13. A thermally-activated gas extraction device, comprising: a
substrate; an exhaust manifold; and a barrier layer supported by
the substrate, the barrier layer having elements formed therein,
the elements including: a bubble capture chamber; a tapered primary
extraction chamber extending from the bubble capture chamber and
including a wide end remote from the bubble capture chamber, the
primary extraction chamber having a cross-sectional area that
increases with increasing distance from the bubble capture chamber,
and a tapered secondary extraction chamber extending from the wide
end of the primary extraction chamber towards the exhaust manifold,
the secondary extraction chamber having a cross-sectional area that
increases with increasing distance from the primary extraction
chamber; and an extraction heater associated with each of the
primary extraction chamber and the secondary extraction chamber and
supported by the substrate.
14. The thermally-activated gas extraction device of claim 13,
additionally comprising a gas-release heater supported by the
substrate in the bubble capture chamber.
15. The thermally-activated gas extraction device of claim 13, in
which: additional tapered extraction chambers are defined in the
barrier layer between the primary extraction chamber and the
secondary extraction chamber; and the gas extraction device
additionally comprises an extraction heater associated with each of
the additional tapered extraction chambers.
16.The thermally-activated gas extraction device of claim 13, in
which: the extraction heater associated with the primary extraction
chamber is located in the bubble capture chamber; the bubble
capture chamber includes a boundary having a spatial energy
potential; the primary extraction chamber includes a mouth adjacent
the bubble capture chamber; and the mouth of the primary extraction
chamber has a spatial energy potential less than the spatial energy
potential of the boundary of the bubble capture chamber.
17. A method of removing gas from a liquid, the method comprising:
providing: a bubble capture chamber, an exhaust manifold, and a
tapered extraction chamber extending from the bubble capture
chamber towards the exhaust manifold, the tapered extraction
chamber having walls that taper outwards with increasing distance
from the bubble capture chamber; accumulating a bubble of gas in
the bubble capture chamber; heating a portion of the liquid in the
tapered extraction chamber to nucleate a bubble of vapor; heating
the bubble of vapor to explosively expand the bubble of vapor into
contact with the walls of the tapered extraction chamber and into
contact with the bubble of gas to form a composite bubble, contact
with the walls of the tapered extraction moving the composite
bubble towards the exhaust manifold; and discontinuing heating of
the composite bubble to condense the vapor in the composite
bubble.
18. The method of claim 17, in which heating the liquid and heating
the bubble include: providing a resistor located in the tapered
extraction chamber, and feeding electric current through the
resistor.
19. The method of claim 18, in which: the resistor is located on a
substrate; and feeding the electric current through the resistor
includes pulsing the current to reduce heat transfer from the
resistor to the substrate.
20. The method of claim 17, in which heating the liquid and heating
the bubble include: providing an energy dissipator located in the
tapered extraction chamber; and feeding energy to the energy
dissipator.
21. The method of claim 17, in which: the method additionally
comprises detecting a size of the bubble of gas in the bubble
capture chamber; and heating the liquid and heating the bubble are
performed after the bubble of gas in the bubble capture chamber has
been detected to have grown to a predetermined size.
22. The method of claim 17, in which heating the liquid and heating
the bubble are repetitively performed at a predetermined
timing.
23. The method of claim 17, in which: the tapered extraction
chamber is a secondary extraction chamber, the bubble of vapor
nucleated therein is a second bubble of vapor, and the composite
bubble formed therein is a second composite bubble; a primary
extraction chamber is additionally provided, the primary extraction
chamber being interposed between the secondary extraction chamber
and the bubble capture chamber, the primary extraction chamber
having a cross-sectional area that increases with increasing
distance from the bubble capture chamber; and prior to heating the
portion of the liquid in the secondary extraction chamber to
nucleate a bubble of vapor, the method additionally comprises:
heating a portion of the liquid in the primary extraction chamber
to nucleate a first bubble of vapor, heating the first bubble of
vapor to explosively expand the first bubble of vapor into contact
with the walls of the primary extraction chamber and into contact
with the bubble of gas to form a first composite bubble, contact
between the first composite bubble and the walls of the tapered
extraction chamber moving the first composite bubble towards the
secondary extraction chamber, and discontinuing heating of the
first composite bubble to condense the vapor in the first composite
bubble to recover the bubble of gas.
24. A method of removing gas from a liquid, the method comprising:
providing: a bubble capture chamber including a boundary having a
spatial energy potential, an exhaust manifold, and a tapered
extraction chamber extending from the bubble capture chamber
towards the exhaust manifold, the tapered extraction chamber
including: walls that taper outwards with increasing distance from
the bubble capture chamber; and a mouth adjacent the bubble capture
chamber, the mouth being dimensioned to have a spatial energy
potential less than the spatial energy potential of the boundary of
the bubble capture chamber; accumulating a bubble of gas in the
bubble capture chamber; and heating the bubble of gas in the bubble
capture chamber to expand the bubble into the tapered extraction
chamber, the bubble after expansion including a first surface
having a first radius of curvature in the bubble capture chamber
and a second surface having a second radius of curvature in contact
with the walls of the tapered extraction chamber, the heating being
continued at least until the bubble of gas expands to a size at
which the second radius of curvature becomes greater than the first
radius of curvature and a resulting pressure difference moves at
least part of the bubble from the bubble capture chamber to the
tapered extraction chamber.
25. The method of claim 24, in which: the method additionally
comprises detecting a size of the bubble of gas accumulated in the
bubble capture chamber; and heating the bubble of gas is performed
in response to detecting that the bubble of gas accumulated in the
bubble capture chamber has grown to a size that substantially fills
the bubble capture chamber.
Description
FIELD OF THE INVENTION
[0001] The invention relates to a device for extracting gas from a
microfluidics system, and, in particular, to removing dissolved air
from the ink flowing into the print head of an inkjet printer.
BACKGROUND OF THE INVENTION
[0002] The print head of an inkjet printer forms part of a print
cartridge mounted in a carriage. The carriage moves the print
cartridge back and forth across the paper. The print head includes
many orifices, typically arranged in line aligned parallel to the
direction in which the paper is moved through the printer and
perpendicular to the direction of motion of the print head. Each
orifice constitutes the outlet of a firing chamber in which is
located a firing element such as a heating element or piezoelectric
element. The firing element operates in response to an electrical
signal to cause minute droplets of ink to be ejected from the
orifice.
[0003] Ink from a reservoir is supplied to the firing chambers
through an ink manifold in the print head. The ink reservoir may be
located in the ink cartridge behind the print head. Alternatively,
the ink reservoir may be independent of the print cartridge and be
mounted in a static location. In this case, the ink flows through a
flexible tube from the ink reservoir to the print head.
[0004] During manufacture, ink with a carefully controlled
concentration of dissolved air is sealed in the ink reservoir. When
some types of ink reservoir are installed in a printer, either
independently or as part of the ink cartridge, the seal is broken
to admit ambient air to the ink reservoir. This is necessary to
enable air to replace the ink drawn from the ink reservoir during
printing. Exposing of the ink in the ink reservoir to the ambient
air causes the amount of air dissolved in the ink to increase over
time.
[0005] When additional air becomes dissolved in the ink stored in
the ink reservoir, this air is released from solution by the action
of the firing mechanism in the firing chamber of the print head.
The excess air accumulates as bubbles in the firing chamber. The
bubbles can migrate from the firing chamber to other locations in
the print head where they can block the flow of ink. Moreover, the
additional air can be released from solution by environmental
changes, such as temperature changes or changes of atmospheric
pressure. The additional air can then form bubbles that can block
the flow of ink in or to the print head.
[0006] It is undesirable to allow air bubbles to remain in the
print head. Air bubbles can degrade the print quality, can cause a
partially-full print cartridge to appear empty, requiring premature
replacement of the ink cartridge. Air bubbles can also cause ink to
leak from the orifices when the printer is not printing, especially
when environmental changes occur.
[0007] What is needed, therefore, is a gas extraction device for
use in a microfluidics system. Such a device should at least be
capable of extracting bubbles of gas from locations in the
microfluidics system where bubbles of gas accumulate and of
delivering the gas to the atmosphere against any pressure
difference that may exist. Optionally, the device should also be
capable of releasing dissolved gas from the liquid in the
microfluidics system prior to extracting the gas. In particular,
what is needed is a gas extraction device for an ink jet printer.
The gas extraction device should at least be capable of extracting
bubbles of additional air from locations in the ink storage and
delivery system of the ink jet printer where bubbles of air
released from the ink accumulate, and of delivering the additional
air to the atmosphere against the negative pressure difference that
generally exists between the ink storage and delivery system and
the atmosphere. Optionally, the gas extraction device should also
be capable of releasing the dissolved air from the ink as the ink
flows through the ink delivery system in or to the print head, or
from the ink stored in the ink storage reservoir. What is also
needed is a gas extraction device capable of extracting gas from a
microfluidics system, and that lacks moving parts, is easy and
cheap to fabricate, and that has low energy consumption. Finally,
what is needed is a gas extraction device for an ink jet printer
that can easily be structurally integrated with other parts of the
print head, and that can be fabricated using the same manufacturing
processes as other parts of the print head.
SUMMARY OF THE INVENTION
[0008] The invention provides a thermally-activated gas extraction
device that comprises a bubble capture chamber, an exhaust
manifold, a tapered extraction chamber and an extraction heater
associated with the tapered extraction chamber. The tapered
extraction chamber extends from the bubble capture chamber towards
the exhaust manifold and has a cross-sectional area that increases
towards the exhaust manifold.
[0009] The invention also provides a thermally-activated gas
extraction device that comprises a substrate, an exhaust manifold,
a barrier layer supported by the substrate, and extraction heaters
supported by the substrate. Elements are formed in the barrier
layer. The elements include a bubble capture chamber, a tapered
primary extraction chamber and a tapered secondary extraction
chamber. The primary extraction chamber extends from the bubble
capture chamber, includes a wide end remote from the bubble capture
chamber and has a cross-sectional area that increases towards the
exhaust manifold. The secondary extraction chamber extends from the
wide end of the primary extraction chamber towards the exhaust
manifold, and also has a cross-sectional area that increases
towards the exhaust manifold. Ones of the extraction heaters are
associated with each of the primary extraction chamber and the
secondary extraction chamber.
[0010] The invention further provides a first method of removing
gas from a liquid. In the method, a bubble capture chamber, an
exhaust manifold, and a tapered extraction chamber are provided.
The tapered extraction manifold extends from the bubble capture
chamber towards the exhaust manifold, and includes walls that taper
outwards with increasing distance from the bubble capture chamber.
A bubble of gas is accumulated in the bubble capture chamber. A
portion of the liquid in the tapered extraction chamber heated to
nucleate a bubble of vapor. The bubble of vapor is heated to
explosively expand the bubble of vapor into contact with the walls
of the tapered extraction chamber and into contact with the bubble
of gas to form a composite bubble. Contact with the walls of the
tapered extraction moves the composite bubble towards the exhaust
manifold. Finally, heating of the composite bubble is discontinued
to condense the vapor in the composite bubble.
[0011] Finally, the invention provides a second method of removing
gas from a liquid. In the method, an exhaust manifold and a tapered
extraction chamber are provided. The bubble capture chamber
includes a boundary having a spatial energy potential. The tapered
extraction chamber extends from the bubble capture chamber towards
the exhaust manifold, and includes walls and a mouth. The walls
taper outwards with increasing distance from the bubble capture
chamber. The mouth adjoins the bubble capture chamber and is
dimensioned to have a spatial energy potential less than the
spatial energy potential of the boundary of the bubble capture
chamber. A bubble of gas is accumulated in the bubble capture
chamber. The bubble of gas in the bubble capture chamber is heated
to expand the bubble into the tapered extraction chamber. After
expansion, the bubble includes a first surface having a first
radius of curvature in the bubble capture chamber and a second
surface having a second radius of curvature in contact with the
walls of the tapered extraction chamber. Heating is continued at
least until the bubble of gas expands to a size at which the second
radius of curvature becomes greater than the first radius of
curvature and a resulting pressure difference moves at least part
of the bubble from the bubble capture chamber to the tapered
extraction chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] FIG. 1A is a plan view of a first embodiment of a gas
extraction device according to the invention having a transparent
cover that shows the inner structure.
[0013] FIG. 1B is a cross-sectional view of the first embodiment of
the gas extraction device according to the invention.
[0014] FIG. 1C is a cross sectional view showing details of the
extraction heater of the gas extraction device according to the
invention.
[0015] FIG. 2A is a plan view of the elements defined in the
barrier layer in the first embodiment of a gas extraction device
according to the invention.
[0016] FIG. 2B schematically shows the electrical arrangement of
the first embodiment of a gas extraction device according to the
invention.
[0017] FIGS. 3A-3I and 3K are plan views of the first embodiment of
a gas extraction device according to the invention illustrating the
first method of removing gas according to the invention.
[0018] FIGS. 3J and 3L are cross sectional views similar to FIG. 1B
and illustrating part of the operation of the first embodiment of
the gas extraction device according to the invention.
[0019] FIG. 4A is a plan view of a second embodiment of a gas
extraction device according to the invention having a transparent
cover that shows the inner structure.
[0020] FIG. 4B is a cross-sectional view of the second embodiment
of the gas extraction device according to the invention.
[0021] FIG. 4C is a plan view of the elements defined in the
barrier layer in the second embodiment of a gas extraction device
according to the invention.
[0022] FIG. 5 illustrates part of the operation of the second
embodiment of a gas extraction device according to the
invention.
[0023] FIG. 6 is a plan view of a third embodiment of a gas
extraction device according to the invention having a transparent
cover that shows the inner structure and additionally schematically
shows the electrical arrangement of the embodiment.
[0024] FIGS. 7A-7D are plan views of the third embodiment of a gas
extraction device according to the invention illustrating the
second method of removing gas according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0025] The invention is based on the observation that, in a gas
extraction device that includes a tapered extraction chamber
coupled by a narrow neck to a bubble capture chamber in which an
air bubble is captured, a vapor bubble nucleated in a liquid
confined in the extraction chamber joins together with the air
bubble as it expands, and draws at least part of the air bubble
into the extraction chamber as it moves towards the wider end of
the extraction chamber. Contact between the composite vapor/air
bubble and the tapered walls of the extraction chamber then moves
the composite bubble against the pressure gradient into an exhaust
manifold at an ambient, e.g., atmospheric, pressure.
[0026] Before the invention is described in detail, some basic
properties of gas bubbles in liquids in confined spaces will be
discussed. When a gas bubble exists in a liquid, a bubble surface
exists at the interface between the gas and the liquid. A pressure
difference exists at the bubble surface. The pressure difference
can be characterized by the radius r of the surface, the angle of
contact .theta., and the surface tension .sigma.(T), i.e.,
P=(2.sigma.(T)cos .theta./r). The surface tension .sigma.(T)
depends on the temperature T of the surface. The position of the
bubble surface can be manipulated by varying one or more of the
pressure difference, the surface tension and the radius of
curvature.
[0027] If the bubble surface intersects a solid material, such as
the wall of a channel, the angle of intersection between the bubble
surface and the solid material depends on the wetting properties of
the solid material with respect to both the gas in the bubble and
the liquid surrounding the bubble. At one value of the angle of
intersection, called the equilibrium contact angle, the bubble will
stay at rest. If the angle of intersection changes, so that it
becomes greater or less than the equilibrium contact angle, the
bubble will tend to move.
[0028] As noted above, the pressure difference across the bubble
surface is inversely proportional to the radius of curvature of the
bubble surface. The temperature of the bubble surface of a bubble
of water vapor in water is approximately 100.degree. C. The surface
tension of water at 100.degree. C. is about 59 milliNewtons per
meter (mN/m). If the bubble has a radius of 25 .mu.m, then the
pressure P.sub.r inside the bubble relative to the pressure of the
surrounding water is
2.times.59.times.10.sup.-3/25.times.10.sup.-6=4.72
[0029] kiloPascals (kPa). This pressure difference is equal to the
pressure exerted by a column of water approximately 46 cm tall. If
the radius of the bubble is halved to 12.5 .mu.m, then the pressure
P.sub.r inside the bubble doubles to 9.44 kPa.
[0030] Also as noted above, the pressure difference P.sub.r across
the bubble surface also depends on the surface tension of the
bubble surface, which varies with temperature. For example, the
surface tension of water decreases by approximately 22% over the
temperature range of 0 to 100.degree. C., i.e., by approximately
0.22% /.degree. C. Thus, the change in the pressure difference
P.sub.r caused by the effect of even a relatively large temperature
change on the surface tension is small compared to the change in
the pressure difference P.sub.r caused by changing the radius of
curvature of the bubble surface.
[0031] A bubble located in a capillary channel is said to be
wall-confined if the is bubble is large enough for two,
substantially opposite sides of the bubble to touch the walls of
the channel simultaneously. For example, in an elongate
liquid-filled channel having a circular cross section, most of the
periphery of a bubble that is wall confined contacts the channel
wall, yet the bubble is free to move along the length of the
channel. If the bubble shrinks so that it touches the channel wall
along less than 180.degree. of its periphery, it is no longer
wall-confined.
[0032] Like any fluid, bubbles tend to flow from a region of higher
energy potential to a region of lower energy potential. The energy
required to introduce a wall-confined bubble of a given volume into
a given location in a channel is the product of the spatial energy
potential of the location of the channel and the volume of the
bubble. The spatial energy potential of a location is the energy
required to introduce a bubble of unit volume into the location.
Thus, the energy in Joules required to introduce a bubble having a
volume of y ml into a location in a channel where the spatial
energy potential is x Joules of energy per milliliter (ml) of
bubble volume is given by the product xy. Moreover, if the channel
includes a second location where the spatial energy potential z is
less than that of the first location, i.e., z<x, the bubble will
tend to move towards the second location from the first location
because its overall energy is less in the second location than in
the first.
[0033] The spatial energy potential of a location for a
wall-confined bubble in a fluid is set both by geometry and by
temperature. For a bubble of gas in a hydrophilic liquid, a narrow
channel has a higher spatial energy potential than a wider channel,
and a cool location has a higher spatial energy potential than a
warmer location.
[0034] The invention will now be described with reference to
examples in which the gas extraction device is used to remove
additional air from the ink in an ink jet printer. The gas
extraction device is shown located in an ink delivery channel
through which ink is delivered to or through the print head.
However, the gas extraction device when used in an ink jet printer
is not limited to such locations, and may additionally or
alternatively be located elsewhere. For example, the gas extraction
device may be located in an ink channel adjacent the ink storage
reservoir. In this location, ink circulates through the ink channel
and the gas extraction device operates to maintain the air
concentration in the ink in the desired range. Moreover, it will be
apparent to one of ordinary skill in the art that the gas
extraction device described herein can be used to extract gas from
other types of microfluidics devices in addition to the ink storage
and delivery system of an ink jet printer.
[0035] FIGS. 1A and 1B show a first embodiment 100 of a gas
extraction device according to the invention. Additional details
are shown in FIGS. 1C, 2A and 2B. The embodiment shown is an active
gas extraction device that includes a heater or other element that
releases dissolved air from the ink passing through the ink
delivery channel into or through the print head of the ink-jet
printer. However, the invention also provides a passive gas
extraction device that lacks such a heater or gas-releasing
element. A passive gas extraction device can be located at a point
in the ink delivery system where bubbles of air released from the
ink accumulate. Such air could be released from the ink by the ink
firing element, for example, or by environmental changes, as
described above. Whether active or passive, the gas extraction
device according to the invention extracts the bubbles of air from
the ink delivery system and transfers them to an exhaust manifold.
The gas extraction device therefore prevents the bubbles of air
from causing problems described above.
[0036] The gas extraction device 100 is connected to a liquid flow
channel, through which the liquid carrying the dissolved gas flows.
In the example shown in FIGS. 1A and 1B, in which the gas
extraction device operates in the ink system of an inkjet printer,
the ink delivery channel 50 corresponds to the fluid flow channel.
The gas extraction device includes the bubble capture chamber 104
located in the ink delivery channel, the tapered primary extraction
chamber 110, the extraction heater 118 associated with the primary
extraction chamber, and the exhaust manifold into which the gas
extraction device deposits the gas extracted from the liquid. In
the embodiment shown in FIGS. 1A and 1B, the extraction heater 118
is associated with the primary extraction chamber by locating this
heater in the primary extraction chamber.
[0037] Ink flows through the ink delivery channel 50 between the
ink inlet 52 and the ink outlet 54 in the downstream direction
indicated by the arrow 56. In the example shown, the ink inlet and
the ink outlet are shown extending through the substrate 102 on
which the gas extraction device is constructed. However, this is
not critical to the invention. Only one of the ink inlet and the
ink outlet may extend through the substrate. Alternatively, neither
the ink outlet nor the ink inlet need extend through the substrate,
and the ink may flow parallel to the surface of the substrate.
Alternatively, either or both of the ink inlet and ink outlet may
extend through the cover 154.
[0038] Referring additionally to FIG. 2A, the ink delivery channel
50 is shaped to define the bubble capture chamber 104. In the
example shown, the bubble capture chamber includes the wide center
portion 107 flanked by the narrower upstream and downstream
portions 106 and 108. The downstream portion 108 is narrower than
the upstream portion. The lower spatial energy potential of the
center portion 107 compared with that of the narrower upstream and
downstream portions 106 and 108 confines the bubbles of air
released from the ink to the bubble capture chamber. The bubble
capture chamber prevents the air released from the ink from
travelling downstream into the print head, and from migrating
upstream when the power is switched off.
[0039] The primary extraction chamber 110 is coupled to the ink
delivery channel 50 at the bubble capture chamber 104. The primary
extraction chamber is composed of the narrow, parallel-sided neck
112 in series with the tapered chamber 114. The neck is wider than
both the upstream portion 106 and the downstream portion 108 of the
bubble capture chamber. The tapered chamber 114 has a
cross-sectional area that increases towards the exhaust manifold
130, i.e., with increasing distance from the neck 112. In the
example shown, the cross-sectional area is increased by increasing
the width of the tapered chamber. However, the cross-sectional area
could additionally or alternatively be increased by increasing the
height of the tapered chamber. The substantially semi-circular
portion 116 of the tapered chamber 114 extends from the widest part
of the tapered chamber, remote from the neck 112. The neck 112
connects the narrow end of the tapered chamber 114 to the bubble
capture chamber.
[0040] The example shown also includes the secondary extraction
chamber 120 located between the primary extraction chamber 110 and
the exhaust manifold 130. The secondary extraction chamber has a
structure similar to that of the primary extraction chamber, and is
composed of the parallel-sided neck 122 in series with the tapered
chamber 124. The tapered chamber 124 has a cross-sectional area
that increases towards the exhaust manifold 130, i.e., with
increasing distance from the neck 122. In the example shown, the
cross-sectional area is increased by increasing the width of the
tapered chamber. However, the cross-sectional area could
additionally or alternatively be increased by increasing the height
of the tapered chamber. The substantially semi-circular portion 126
of the tapered chamber extends from the widest part of the tapered
chamber, remote from the neck 122. Alternatively, the tapered
chamber 124 may also include a short parallel-sided section (not
shown) interposed between the widest part of the tapered chamber
and the substantially semi-circular portion 126. The neck 122
connects the narrow end of the tapered chamber 124 to the
semicircular portion 116 of the tapered chamber 114.
[0041] The exhaust manifold 130 extends from the end of the tapered
chamber 124 remote from the neck 122 through the thickness of the
substrate 102 into direct or indirect communication with the
atmosphere or other ambient. The exhaust manifold provides a path
for the air removed from the ink delivery channel to vent to the
atmosphere. The exhaust manifold may alternatively extend through
the thickness of the cover 154.
[0042] The ink flowing through the ink delivery channel 50 is
normally at a pressure equivalent to several centimeters of water
below atmospheric pressure. To remove the air extracted from the
ink from the bubble capture chamber 104 and to vent the extracted
air into the atmosphere via the exhaust manifold 130, the gas
extraction device 100 must pump the extracted air against the
pressure difference between the ink pressure in the ink delivery
channel and the pressure in the exhaust manifold. The pressure in
the exhaust manifold is typically atmospheric pressure. In the
embodiment shown in FIGS. 1A and 1B, the serial arrangement of the
primary extraction chamber 110 and the secondary extraction chamber
120 between the bubble capture chamber 104 and the exhaust manifold
130 increases the maximum allowable pressure difference between the
ink pressure in the ink delivery channel and atmospheric pressure
in the exhaust manifold.
[0043] The serial arrangement of the primary extraction chamber 110
and the secondary extraction chamber 120 between the bubble capture
chamber 104 and the exhaust manifold 130 also prevents ink from
leaking from the ink delivery channel 50 to the exhaust manifold.
The flow of ink from the ink delivery channel to the exhaust
manifold is blocked by operating the gas extraction device so that
an air bubble capable of blocking the entrance to the neck 112 is
located in the bubble capture chamber 104 when no bubble capable of
blocking the entrance to the neck 122 is located in the primary
extraction chamber 110, and so that an air bubble capable of
blocking the entrance to the neck 122 is located in the primary
extraction chamber when no bubble capable of blocking the entrance
of the neck 112 is located in the bubble capture chamber.
[0044] In applications in which the maximum allowable pressure
difference is small, or in which the leakage of ink from the ink
delivery channel is unimportant, only one extraction chamber may be
needed. The primary extraction chamber 110 may be omitted, and the
neck 122 of the secondary extraction chamber 120 may be connected
directly to the bubble capture chamber 104. In applications in
which the maximum pressure difference is larger than that which can
be provided by a serial arrangement of two extraction chambers, at
least one additional extraction chamber may be interposed between
the primary and secondary extraction chambers. If multiple
additional extraction chambers are interposed, the primary
extraction chamber, the additional extraction chambers and the
secondary extraction chamber are arranged in series between the
bubble capture chamber and the exhaust manifold.
[0045] In the example shown, the secondary extraction chamber 120
has dimensions similar to that of the primary extraction chamber
110. However, the primary and secondary extraction chambers may
have different dimensions from one another. In the example shown,
in which the ink in the ink delivery channel is at a pressure lower
than the pressure in the exhaust manifold, the secondary extraction
chamber may be dimensioned to have a greater cross-sectional area
than that of the primary extraction chamber. Also, in the example
shown, the primary extraction chamber and the secondary extraction
chamber are both shown extending substantially perpendicular to the
direction of ink flow through the ink delivery channel 50. However,
this is not critical to the invention. The long axis of the
secondary extraction chamber may be orthogonal to, or at some other
non-zero angle to the long axis of the primary extraction chamber.
Such an arrangement may provide a significant reduction in the area
of the gas extraction device 100.
[0046] Energy must be supplied to the air extracted from the ink to
move the air from the bubble capture chamber 104 to the exhaust
manifold 130 against the pressure difference between the ink
pressure in the ink delivery channel 50 and atmospheric pressure in
the exhaust manifold. In the example shown in FIGS. 1A and 1B, the
energy is supplied in the form of heat generated by the extraction
heater 118 located on the part of the substrate 102 that provides
the floor of the primary extraction chamber 110 and the extraction
heater 128 located on the part of the substrate 102 that provides
the floor of the secondary extraction chamber 120. Each extraction
heater is elongate and extends lengthways along the center line of
the respective extraction chamber. Referring now to FIGS. 2A and
2B, the extraction heater 118 extends from the neck 112 to a point
substantially coincident with the widest part of the tapered
chamber 114. The extraction heater 128 extends from the neck 122 to
a point that is preferably but not necessarily adjacent the exhaust
manifold 130.
[0047] The embodiment shown additionally includes the gas release
heater 140 located on the part of the substrate 102 that provides
the floor of the bubble capture chamber 104. The gas release heater
is structurally similar to the extraction heaters 118 and 128. The
gas release heater warms the ink flowing through the ink delivery
channel 50 to cause the ink to release dissolved air. The released
air collects in a bubble that is confined to the bubble capture
chamber. A passive embodiment would lack a gas release heater in
its bubble capture chamber. The bubble capture chamber of a passive
embodiment would capture air released from the ink by other means,
such as by the action of the firing element of the printer, or by
environmental changes.
[0048] In the preferred embodiment, the heaters 118, 128 and 140
are resistors connected to the controller 142 by conductive tracks
located on the surface 150 of the substrate 102, as shown
schematically in FIG. 2B. An exemplary track connecting the
controller to the extraction heater 118 is shown at 143. The
controller is also shown schematically in the Figure. Although the
controller may be physically separate from the substrate 102, and
connected thereto by conductors such as wires, the controller is
preferably built in and on the surface 150 of the substrate using
conventional semiconductor circuit fabrication techniques.
[0049] The controller 142 selectively passes respective electric
currents through the resistors constituting the heaters 118, 128
and 140. The electric currents cause the heaters to generate heat.
In the preferred embodiment, the controller supplied current to the
extraction heaters 118 and 128 in a series of ten 5 ms-wide pulses,
with 5 ms between consecutive pulses. However, the number of
pulses, the pulse duration, the duty cycle, or any combination of
these factors may be changed. Pulsing the current supplied to the
extraction heaters reduces the transfer of heat from the heaters to
the substrate, and maintains a clear temperature differential
between the heaters and the substrate adjacent the heaters.
[0050] The controller 142 may be an open-loop controller that feeds
current to the heaters 118, 128 and 140 at pre-determined times for
pre-determined durations. Alternatively, one or more of the bubble
capture chamber 104, the first extraction chamber 110 and the
second extraction chamber 120 may be equipped with sensors, the
controller may include respective bubble detector circuits that
operate in response to the sensors, and the controller may control
the heaters 118, 128 and 140 in response to the bubble detector
circuits. A bubble detector circuit generates an electrical signal
that depends on the presence of air, i.e., a bubble, or a liquid,
i.e., ink, adjacent its respective sensor. The sensors may be
located on the surface 150 of the substrate 102, or on the portions
of the surface of the cover 154 that provides the ceilings of one
or more of the bubble capture chamber 104, the primary extraction
chamber 110, and the secondary extraction chamber 120.
[0051] An exemplary sensor located in the bubble capture chamber
104 is shown at 144 in FIGS. 1A, 1B and 2B. The sensor is part of a
gas/liquid detector that generates a control signal that changes
state when the air bubble in the bubble capture chamber has grown
to such a size that a majority of the area of the sensor is in
contact with the air contained in the bubble, instead of with the
ink. When the controller 142 operates in response to the control
signal generated by the gas/liquid detector that includes the
sensor 144, the controller feeds current to the extraction heater
118 only when the control signal generated by the gas/liquid
detector changes state, indicating that an air bubble of sufficient
size has accumulated in the bubble capture chamber. The gas/liquid
detectors disclosed in a patent application entitled High Output
Capacitative Gas/Liquid Detector, simultaneously filed with this
disclosure and assigned to the assignee of this disclosure are
especially advantageous in detecting the size of the bubble. Such
gas/liquid detectors operate in response to a high capacitance
effect only detectable at applied voltages less than about 100
millivolts The entire disclosure of the just-mentioned patent
application is incorporated into this disclosure by reference. The
sensor of the gas/liquid detector of the type just described can
additionally or alternatively be incorporated into the primary
extraction chamber 110. The sensor is preferably located at the end
of the primary extraction chamber remote from the neck 112.
[0052] Circuits that can be used in the controller 142 to control
the flow of current through the heaters 118, 128 and 140 at
predetermined times and with predetermined durations, or in
response to a signal generated by a gas/liquid detector, are known
in the art and will not be described here.
[0053] Although the heaters 118, 128 and 140 have been described as
resistors through which current is selectively passed to cause them
to generate heat, the precise mechanism by which the heaters
generate heat is not critical to the invention. The heaters may
include energy dissipaters that convert other forms of energy, such
as optical or RF electromagnetic radiation, or an alternating
magnetic field, into heat using structures and techniques known in
the art.
[0054] The cross sectional views of FIGS. 1B and 1C show additional
details of the construction of a preferred embodiment of the gas
extraction device 100. The preferred embodiment is fabricated by
micromachining techniques that use semiconductor fabrication
processing to make miniature mechanical structures. Such techniques
are known in the art, so the process of making the gas extraction
device will not be described in detail here. The gas extraction
device 100 is one of a large number of identical gas extraction
devices simultaneously fabricated on a wafer of single-crystal
silicon. Part of the wafer constitutes the substrate 102. After the
fabrication process is complete, the wafer and the additional
layers applied to the wafer are broken or cut to yield the
individual gas extraction devices.
[0055] The silicon wafer is anisotropically etched through its
thickness to form the ink inlet, the ink outlet and the exhaust
manifold of each gas extraction device, including the ink inlet 52,
the ink outlet 54 and the exhaust manifold 130 of the gas
extraction device 100. The heaters 118, 128 and 140 of each gas
extraction device, including the heaters 118, 128 and 140 of the
gas extraction device 100, are then fabricated on the surface of
the wafer at precisely defined locations relative to the locations
of the ink outlet, the ink inlet and the exhaust manifold.
Fabrication of the preferred embodiment of the heaters will be
described below.
[0056] The surface of the wafer is then coated with a layer of
barrier material to form the barrier layer in which the ink
delivery channel, including the bubble capture chamber, and the
primary and secondary extraction chambers of each gas extraction
device are defined. The part of the barrier layer in which the ink
delivery channel 50, including the bubble capture chamber 104, and
the primary and secondary extraction chambers 110 and 120 of the
gas extraction device 100 are defined is shown at 152. The barrier
layer may be a layer of photosensitive barrier material, such as
polyimide. The photosensitivity of the barrier material enables the
shapes of the ink delivery channel and the primary and secondary
extraction chambers to be defined in the barrier layer using a
conventional masking and solvent removal process. In a preferred
embodiment, the barrier layer was a layer of a so-called high
aspect ratio photoresist, such as SU-8 epoxy-based photoresist sold
by MicroChem Corp., Newton, Mass. 02164-1418.
[0057] The thickness of the barrier layer is preferably greater
than the widest dimensions of the ink delivery channel and the
primary and secondary extraction chambers. This makes any
wall-confined bubble prolate in shape, and ensures that the spatial
energy potential at any point in the ink delivery channel and the
primary and secondary extraction chambers is principally defined by
the width of the channel or the chamber, respectively. However, in
practice, it is difficult to fabricate the desired elements in a
barrier layer of the necessary thickness. Consequently a thinner
barrier layer is normally used and the bubbles are consequently
oblate. However, the spatial energy potential at any point in the
ink delivery channel and the primary and secondary extraction
chambers still depends on the width of the respective channel or
chamber in such devices.
[0058] A mask (not shown), patterned to define the shapes of the
ink delivery channel and the primary and secondary extraction
chambers of each gas extraction device to be formed on the wafer,
including the ink delivery channel 50 and the primary and secondary
extraction chambers 110 and 120 of the gas extraction device 100,
is aligned relative to the heaters already formed on the surface of
the wafer. The barrier layer is then exposed to light through the
mask. The wafer is then processed with solvents to remove the
portions of the barrier layer corresponding to the shapes defined
by the mask. Removing such portions of the barrier layer forms the
ink delivery channel and the primary and secondary extraction
chambers of each gas extraction device, including the ink delivery
channel 50 and the primary and secondary extraction chambers 110
and 120 of the gas extraction device 100. Removing portions of the
barrier layer additionally exposes the heaters located on the
surface of the wafer. The surface of the wafer provides the floor,
and the barrier layer provides the side walls of the ink delivery
channel, the primary extraction chamber and the secondary
extraction chamber of each gas extraction device formed in the
wafer. FIG. 2A shows the ink delivery channel 50, the primary
extraction chamber 110 and the secondary extraction chamber 120 of
the gas extraction device 100 defined by the portion 152 of the
barrier layer not removed by the solvent.
[0059] The fabrication method just described can easily be adapted
to define the shapes of the ink delivery channel and the extraction
chambers in a layer of non-photosensitive barrier material. In this
case, an additional layer of photoresist is applied to the layer of
barrier material to define the shapes that will be formed in the
barrier layer. Alternatively, the barrier layer may be composed
entirely of a layer of photoresist.
[0060] A cover is then attached to the barrier layer. The cover
provides the ceiling of the ink delivery channel and the primary
and secondary extraction chambers of each gas extraction device
formed on the wafer. The portion of the cover that provides the
ceiling of the ink delivery channel 50 and the primary and
secondary extraction chambers 110 and 120 of the gas extraction
device 100 is shown at 154. The cover may be a second silicon wafer
or a thin sheet of glass or a suitable plastic such as polyimide.
The wafer, together with the barrier layer and the cover are then
broken or cut into individual gas extraction devices, including the
gas extraction device 100.
[0061] FIG. 1C is an enlarged cross-sectional view of part of the
gas extraction device 100 showing details of the structure of the
extraction heater 111 that includes the resistor 146. The structure
of the extraction heater 128 is similar. The surface 150 of the
substrate 102 is covered by the layer 145 of silicon dioxide. This
layer may be formed by subjecting the surface of the substrate 102
to a wet oxidation process, for example. The silicon dioxide layer
145 provides thermal and electrical insulation between the heater
and the substrate.
[0062] A layer of doped polysilicon is then deposited on the
silicon dioxide layer 145 by low-pressure chemical vapor deposition
(LPCVD), for example, and is then annealed to activate the dopants.
Parts of the polysilicon layer are selectively removed using a
plasma dry etch, for example, to define the resistors constituting
the heaters 118, 128 and 140. The polysilicon resistor constituting
the extraction heater 118 is shown at 146. Additional selective
doping may then be applied to the heaters to define their
conductivity profile and, hence, their heat generation profile. A
layer of metal such as aluminum (not shown) is then deposited on
the surface of the substrate and is selectively removed to define
the tracks, such as the track 143 shown in FIG. 2B, electrically
connecting the heaters 118, 128 and 140 to the controller 142 or to
bonding pads (not shown) to provide external connections. As an
alternative to polysilicon, the heaters may be formed of a metal
such as nickel or tungsten, or of some other suitable resistive
material.
[0063] The layer 147 of silicon nitride or other suitable
dielectric material covers the heaters 118, 128 and 140 and the
tracks (not shown) interconnecting the heaters to the controller
142. The silicon nitride may be deposited by sputtering or by
plasma-enhanced chemical vapor deposition (PECVD), for example. The
silicon nitride layer 147 provides electrical insulation and
physical isolation between the heaters and the ink.
[0064] Although the gas extraction device according to the
invention is is preferably made using micromachining, as described
above, other methods may be used to fabricate the gas extraction
device. For example, hard tooling may be fabricated and used to
mold the gas extraction device or components thereof in a suitable
plastic such as polycarbonate.
[0065] The operation of the gas extraction device 100 according to
the invention will now be described with reference to FIGS. 3A
through 3L.
[0066] FIG. 3A shows the bubble 160 of air captured in the bubble
capture chamber 104. The air constituting the bubble has been
released from the ink flowing through the ink delivery channel 50
by the heat generated by the gas release heater 140. As noted
above, the bubble 160 could be constituted of air released from the
ink by the action of elements other than the gas release heater
140.
[0067] FIG. 3B shows the gas extraction device 100 after the
controller 142 (FIG. 2B) has started to feed current through to the
extraction heater 118 located in the primary extraction chamber
110. Heating the ink in the primary extraction chamber boils the
ink, and the resulting ink vapor forms the bubble 162. The bubble
162 grows explosively and quickly encounters the walls of the
tapered chamber 114.
[0068] FIG. 3C shows the bubble 162 after it has contacted the
walls of the tapered chamber 114. Contact between the bubble and
the walls of the tapered chamber causes the bubble to move in the
direction indicated by the arrow 164. The motion of the bubble 162
draws the bubble 160 in the bubble capture chamber 104 towards the
neck 112 of the primary extraction chamber 110. The bubble 162 also
expands into the neck 112.
[0069] FIG. 3D shows the bubble 162 after its expansion into the
neck 112 has expelled the ink 166 from the neck and the bubbles 160
and 162 have connected to form the composite bubble 168. The bubble
168 has been observed to form in a time corresponding to less than
one frame of a 1000 frames/sec high-speed camera.
[0070] FIG. 3E shows how contact with the walls of the tapered
chamber 114 moves the composite bubble 168 in the direction
indicated by the arrow 164. This motion draws the portion of the
composite bubble located in the bubble capture chamber 104 into the
primary extraction chamber 110.
[0071] FIG. 3F shows the composite bubble 168 after the controller
142 (FIG. 2B) has stopped feeding current to the extraction heater
118, and the heater no longer heats the composite bubble. Not
heating the composite bubble causes the vapor component of the
bubble, mainly contributed by the bubble 162, to condense. As a
result, the composite bubble shrinks and becomes mainly a bubble of
air. Most of the air is contributed by the bubble 160 (FIG. 3A),
although nucleating and growing the bubble 162 releases additional
air from the ink. The additional air becomes part of the bubble 162
and, hence, part of the composite bubble 168. The composite bubble
continues to move in the direction indicated by the arrow 164 until
it comes to rest in the semicircular portion 116 of the tapered
chamber 114, where the spatial energy potential is a minimum, or
until it loses contact with the walls of the tapered chamber.
[0072] Although the air bubble 160 (FIG. 3A) has been successfully
removed from the ink delivery channel 50, the air that constituted
the bubble 160, and which now forms part of the composite bubble
168, must be transferred from the primary extraction chamber 110
through the secondary extraction chamber 120 to the exhaust
manifold 130. To remove the composite bubble from the primary
extraction chamber, the controller 142 (FIG. 2B) feeds pulses of
current to the extraction heater 128 located in the secondary
extraction chamber.
[0073] FIG. 3G shows the bubble 170 formed as a result of the
extraction heater 128 heating the ink located in the secondary
extraction chamber 120. Heating the ink in the secondary extraction
chamber boils the ink, and the resulting ink vapor forms the bubble
170. The bubble 170 grows explosively and quickly encounters the
walls of the tapered chamber 124 and expands into the neck 122.
[0074] FIG. 3H shows the bubble 170 after it has grown explosively
and has encountered the walls of the tapered chamber 124 and has
expanded into the neck 122. Expansion into the neck expels the ink
174 from the neck and the bubbles 168 and 170 connect to form the
composite bubble 176. Contact with the walls of the tapered chamber
124 causes the composite bubble 176 to move in the direction
indicated by the arrow 172. This motion draws the portion of the
composite bubble located in the semicircular portion 116 of the
primary extraction chamber 110 into the secondary extraction
chamber 120.
[0075] FIG. 3I shows the composite bubble 176 after the controller
142 (FIG. 2B) has stopped feeding current to the extraction heater
128, and the heater no longer heats the composite bubble. Not
heating the composite bubble causes the vapor component of the
bubble, mainly contributed by the bubble 170, to condense. As a
result, the composite bubble 176 shrinks, and becomes mainly a
bubble of air. Most of the air is contributed by the bubble 168
(FIG. 3F), although nucleating and growing the bubble 170 releases
additional air from the ink that becomes part of the bubble 170
and, hence, part of the composite bubble. The composite bubble
continues to move in the direction indicated by the arrow 172
towards the exhaust manifold 130, propelled by the walls of the
tapered chamber 124.
[0076] FIG. 3J shows that, as the composite bubble 176 begins to
overlap the exhaust manifold 130, the radius of curvature of the
portion 180 the surface of the composite bubble rapidly increases.
The pressure difference caused by the differing radii of curvature
of the portions 180 and 182 of the surface of the composite bubble
propels the composite bubble into the exhaust manifold 130.
[0077] FIGS. 3K and 3L show the momentum of the composite bubble
carrying the composite bubble into the exhaust manifold 130 in the
direction indicated by the arrow 184.
[0078] It has been observed that the composite bubble 168 often
fragments before the entire composite bubble has moved from the
bubble capture chamber 104 to the primary extraction chamber 110.
When the composite bubble fragments, part of the composite bubble
moves into the primary extraction chamber, leaving behind a smaller
version of the bubble 160 in the bubble capture chamber 104. The
controller 142 re-energizes the extraction heater 118 to repeat the
sequence illustrated in FIGS. 3B-3F and move the bubble left behind
in the bubble capture chamber to the primary extraction chamber
110. The controller may repeat the sequence illustrated in FIGS.
3B-3F several times to remove the bubble 160 completely from the
bubble capture chamber. Moreover, the controller may repeat the
sequence illustrated in FIGS. 3G-3I to remove the composite bubble
168 completely from the primary extraction chamber.
[0079] FIGS. 4A, 4B and 4C show a second embodiment 200 of a gas
extraction device according to the invention. In this embodiment,
the bubble capture chamber 204 is separated from the ink delivery
channel 250 to allow ink to continue to flow through the ink
delivery channel when a large air bubble fills the bubble capture
chamber. Elements of the gas extraction device 200 that correspond
to elements of the gas extraction device 100 shown in FIGS. 1A-1C
are indicated using the same reference numerals and will not be
described in detail again here.
[0080] In the gas extraction device 200, the ink delivery channel
250 extends between the ink inlet. 52 and the ink outlet 54. The
ink delivery channel is substantially wider than the ink delivery
channel 50 shown in FIGS. 1A-1C. The primary extraction chamber 110
and the secondary extraction chamber 120 extend in series from a
point in the ink delivery channel between the ink inlet and the ink
outlet and the exhaust manifold 130.
[0081] The bubble capture chamber 204 is located in the ink
delivery channel 250 at the junction between the primary extraction
chamber 110 and the ink delivery channel. The bubble capture
chamber is delineated from the ink delivery channel by an
arrangement of pillars. In the example shown in FIGS. 4A-4C, the
periphery of the bubble capture chamber is defined by an
arrangement of five pillars 292-296, each having a circular cross
section in the plane parallel to the surface 150 of the substrate
102. The pillars are approximately located on a segment of a
circle. However, the bubble capture chamber can be defined by a
different number of pillars from that shown, pillars having a
cross-sectional shape from that shown, and a different arrangement
of pillars from that shown.
[0082] The pillars 292-296 delineating the bubble capture chamber
204 from the ink delivery channel 250 are spaced more closely than
the width of the neck 112 of the primary extraction chamber so that
the neck has a spatial energy potential lower than that of the
boundary of the bubble capture chamber defined by the pillars and
the gaps between them. Moreover, the pillars are spaced and
dimensioned to allow ink flowing through the ink delivery channel
from the ink inlet 52 to the ink outlet 54 also to flow freely
through the bubble capture chamber 204. The ink that flows through
the bubble capture chamber comes into contact with the gas release
heater 140. Heat generated by the gas release heater releases air
from the ink to generate the bubble 260 shown in FIG. 5. The
regions between adjacent pillars, and between the pillars and the
ink delivery channel are regions of high spatial energy potential
that effectively confine the bubble 260 to the bubble capture
chamber. The bubble capture chamber has a substantially lower
spatial energy potential than the regions between the pillars.
[0083] The shapes of the pillars 292-296 are defined in the barrier
layer 152 in the same operation as the shapes of the ink delivery
channel 250, the primary extraction chamber 110 and the secondary
extraction chamber 120. FIG. 4C shows the shapes of the pillars,
the ink delivery channel, the primary extraction chamber and the
secondary extraction chamber as defined in the barrier layer. The
heaters 118, 128 and 140 shown in FIG. 4A are omitted from FIG. 4C
to simplify the drawing.
[0084] The electrical arrangement of the embodiment shown in FIGS.
4A-4C is the same as that shown in FIG. 2B. FIGS. 4A and 4B show
the sensor 244 of a gas/liquid detector (not shown) that detects
the size of the bubble accumulated in the bubble capture chamber.
The gas/liquid detector generates a control signal that is fed to a
control circuit similar to the control circuit 142 shown in FIG.
2B. The control circuit activates the extraction heater 118 in
response to a change in state of the control signal.
[0085] The embodiment shown in FIGS. 4A-4C can be made using the
process described above for making the embodiment shown in FIGS.
1A-1C. Only the masks that define the position of the gas release
heater 140 and the shapes formed in the barrier layer 152 need be
changed.
[0086] FIG. 5 shows the part of the operation of the embodiment 200
of the gas extraction device shown in FIGS. 4A-4C. FIG. 5 shows a
bubble of air removed from the ink accumulated in the bubble
capture chamber 204. As noted above, ink flowing through the ink
delivery channel 250 from the ink inlet 52 to the ink outlet 54
also flows freely through the bubble capture chamber. The ink that
flows through the bubble capture chamber comes into contact with
the gas release heater 140, and heat generated by the heater
releases air from the ink. The air released from the ink
accumulates to form the bubble 260. The high spatial energy
potential of the gaps between the pillars 292-296 prevents the
bubble from moving out of the bubble capture chamber 204. Even when
the bubble 260 completely fills the bubble capture chamber, ink is
still able to flow around the bubble capture chamber from the ink
inlet 52 to the ink outlet 54.
[0087] The bubble 260 is transferred from the bubble capture
chamber 204 to the exhaust manifold 130 by the controller 142 (FIG.
2B) feeding current to the extraction heater 118 to nucleate and
explosively grow a bubble in the primary extraction chamber 110,
and then feeding current to the extraction heater 128 to nucleate
and explosively grow a bubble in the secondary extraction chamber
120. The process of transferring the bubble 260 to the exhaust
manifold is the same as that described above with reference to
FIGS. 3B-3L, and therefore will not be described again here. The
process of transferring the bubble to the exhaust manifold may be
performed at predetermined time intervals, or in response to the
sensor 244 located in the bubble capture chamber detecting when the
air bubble that accumulates in the bubble capture chamber has grown
to size that substantially fills the bubble capture chamber, and
therefore needs to be removed.
[0088] In the embodiments described above, the extraction heater
118 is associated with the primary extraction chamber 110 by
locating it in the primary extraction chamber. However, the
extraction heater associated with the primary extraction chamber
may alternatively be located in the bubble capture chamber 204, as
in the embodiment 300 shown in FIG. 6. Locating the extraction
heater associated with the primary extraction chamber in the bubble
capture chamber allows a single physical heater element to perform
the functions of the extraction heater and the gas release heater.
Elements of the embodiment shown in FIG. 6 that correspond to
elements of the embodiment shown in FIGS. 4A-4C are indicated by
the same reference numerals and will not be described again
here.
[0089] In the gas extraction device 300 shown in FIG. 6, the
extraction heater 218 associated with the primary extraction
chamber 210 is located in the bubble capture chamber 204. The
extraction heater 218 performs the functions of both the gas
release heater 140 and the extraction heater 118 in the embodiments
described above.
[0090] The primary extraction chamber 210 differs from the primary
extraction chamber 110 shown in FIGS. 4A-4C in that the tapered
chamber 214 connects directly to the part of the ink delivery
channel 250 occupied by the bubble capture chamber. The primary
extraction chamber 210 also differs from the primary extraction
chamber 110 in that the rate at which its tapered chamber 214
widens with increasing distance from the ink delivery channel is
greater at its narrow end adjacent the ink delivery channel, and is
less at its wide end, remote from the ink delivery channel.
[0091] The mouth 291 of the tapered chamber 214 is wider than the
width of the neck 112 of the primary extraction chamber 110 (FIG.
4A) to ensure that the mouth is wider than the gaps between the
pillars, such as the pillars 292 and 293, defining the boundary of
the bubble capture chamber 204 in the ink delivery channel 250.
This relationship ensures that the spatial energy potential of the
mouth is less than the spatial energy potential of any of the gaps
between the pillars. In other words, the mouth is dimensioned so
that its spatial energy potential is less than the minimum spatial
energy potential of the boundary of the bubble capture chamber.
[0092] The extraction heaters 218 and 128 generate heat in response
to electric currents supplied the controller 242. The controller
preferably operates in response to one or more gas/liquid detectors
as described above. FIG. 6 shows the sensor 244 of one gas/liquid
detector (not shown) located in the bubble capture chamber 204. The
sensor 244 detects the size of the bubble (260 in FIG. 7A) that
accumulates in the bubble capture chamber 204. The output signal of
the gas/liquid detector preferably changes state when the bubble
substantially fills the bubble capture chamber. The sensor of a
second gas/liquid detector (not shown) may optionally be located in
the primary extraction chamber 210, remote from the mouth 291.
[0093] The embodiment shown in FIG. 6 can be made using the process
described above for making the embodiment shown in FIGS. 1A-1C.
Only the masks that define the positions of the heaters on the
substrate and the shapes formed in the barrier layer need be
changed.
[0094] Operation of the embodiment 300 of the gas extraction device
shown in FIG. 6 will now be described with reference to FIGS. 6 and
7A-7D. The controller 242, the sensor 244, and the connections
between the controller and the heaters 128 and 290 and the sensor
are omitted from FIGS. 7A-7D to simplify the drawings. Initially,
the controller 242 feeds a relatively low current through the
extraction heater 218. When fed with a relatively low current, the
extraction heater 218 functions as a gas release heater similar to
the gas release heater 140 shown in FIG. 4A, for example. Heat
generated by the extraction heater 218 releases dissolved air from
the ink flowing through the ink delivery channel from the ink inlet
52 to the ink outlet 54. The air released from the ink accumulates
in the bubble 260 trapped in the bubble capture chamber 204.
[0095] The output signal of the gas/liquid detector that includes
the sensor 244 changes state when the bubble 260 grows to a size
that substantially fills the bubble capture chamber 204, as shown
in FIG. 7A. In response to the change of state of the output signal
of the gas/liquid detector, the controller 242 increases the
current fed to the extraction heater 218. When fed with a
relatively high current, the extraction heater 218 functions as the
extraction heater associated with the primary extraction chamber
210, similar to the extraction heater 118 shown in FIG. 4A.
[0096] The additional heat generated by the extraction heater 218
causes the air constituting the bubble 260 to expand. Since the
region with the lowest spatial energy potential surrounding the
bubble is the mouth 291 of the primary extraction chamber 210, the
bubble expands preferentially into the primary extraction chamber,
as shown in FIG. 7B. However, the pressure difference resulting
from the radius of curvature of the surface 297 of the bubble in
the primary extraction chamber being less than that of the surface
298 of the bubble in the bubble capture chamber holds the bubble in
the bubble capture chamber.
[0097] Continued heating of the bubble 260 by the extraction heater
218 causes the bubble to expand further. As the bubble expands, the
surface 297 of the bubble in the primary extraction chamber 110
advances into the tapered chamber 214 and comes into contact with
the walls of the tapered chamber. The radius of curvature of the
surface 297 progressively increases as the surface 297 advances
along the progressively-widening walls of the tapered chamber. When
the radius of curvature of the surface 297 exceeds that of the
surface 298 of the bubble in the bubble capture chamber 204, the
direction of the pressure difference between the surfaces reverses.
The pressure difference between the surfaces starts to move the
bubble 260 out of the bubble capture chamber 204 and into the
primary extraction chamber 210, as indicated by the arrow 299 shown
in FIG. 7C.
[0098] As the bubble 260 moves into the primary extraction chamber
210, the radius of curvature of the surface 297 continues to
increase, which increases the pressure difference across the
bubble. The increasing pressure difference accelerates the bubble
as the bubble enters the primary extraction chamber. Eventually,
however, movement of the bubble 260 into the primary extraction
chamber moves the bubble out of contact with the extraction heater
218. When this occurs, the bubble rapidly cools and loses contact
with the walls of the tapered chamber 214. However, the momentum of
the bubble carries it further into the primary extraction chamber
210, as shown in FIG. 7D. Additional bubbles transferred from the
bubble capture chamber to the primary extraction chamber merge with
the bubble 260 to form an enlarged bubble (not shown). Contact
between the enlarged bubble and the walls of the tapered chamber
214 move the enlarged bubble towards the end of the tapered chamber
remote from the mouth 291. Eventually, the enlarged bubble grows to
a size that substantially fills the end of the tapered chamber
remote from the mouth. The controller 242 then activates the
extraction heater 128 to extract the enlarged bubble from the
primary extraction chamber through the secondary extraction chamber
120 to the exhaust manifold 130 as described above. Several bubbles
may accumulate in the primary extraction chamber before the
extraction heater 128 is activated.
[0099] The controller 242 may detect the loss of contact between
the extraction heater 218 and the bubble 260 by monitoring the
temperature of the heater. The temperature of the heater will drop
as more of the heater comes into contact with the ink in the bubble
capture chamber. When the controller detects the loss of contact,
it reduces the power to the extraction heater 218 and the
extraction heater once more functions as a gas release heater to
generate another bubble of gas in the bubble capture chamber
204.
[0100] The invention is described above with reference to
illustrative embodiments in which air removed from the ink flowing
into or through the print head of an inkjet printer is transferred
to an exhaust manifold at atmospheric pressure. However, the
invention may be used in other microfluidics systems to transfer
other gases removed from other liquids to an exhaust manifold held
at an ambient pressure other than atmospheric pressure.
[0101] The invention is described above with reference to
illustrative embodiments in which a single gas extraction device
extends between the ink delivery channel and the exhaust manifold.
However, the invention is not limited to this. Multiple parallel
gas extraction devices may extend between the ink delivery channel
and the exhaust manifold. Moreover, the pressure in the exhaust
manifold may be different from atmospheric pressure.
[0102] Although this disclosure describes illustrative embodiments
of the invention in detail, it is to be understood that the
invention is not limited to the precise embodiments described, and
that various modifications may be practiced within the scope of the
invention defined by the appended claims.
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