US20030101559A1 - Custom garment design and fabric printing system - Google Patents

Abstract

This patent describes an alternative form for the automatic creation of garments. The garment creation system includes mapping portions of an arbitrary image sensed by an image sensor device onto a garment and outputting a depiction of the garment. Additionally, a garment fabric printer is adapted to to print out corresponding pieces of the garment including the mapped portions. The printing can include printing out instructions for joining the pieces together on the fabric and printing such that joined pieces of fabric appear to be derived from a continuous pattern.

Description

• Continuation Application of U.S. Ser. No. 09/112,759 filed on Jul. 10, 1998[0001]
CROSS REFERENCES TO RELATED APPLICATIONS
• The following co-pending US patent applications, identified by their US patent application serial numbers (USSN), were filed simultaneously to the present application on Jul. 10, 1998, and are hereby incorporated by cross-reference: Ser. Nos. 09/113,060; 09/113,070; 09/113,073; 09/112,748; 09/112,747; 09/112,776; 09/112,750; 09/112,746; 09/112,743; 09/112,742; 09/112,741; 09/112,740; 09/112,739; 09/113,053; 09/112,738; 09/113,067; 09/113,063; 09/113,069; 09/112,744; 09/113,058; 09/112,777; 09/113,224; 09/112,804; 09/112,805; 09/113,072; 09/112,785; 09/112,797; 09/112,796; 09/113,071; 09/112,824; 09/113,090; 09/112,823; 09/113,222; 09/112,786; 09/113,051; 09/112,782; 09/113,056; 09/113,059; 09/113,091; 09/112,753; 09/113,055; 09/113,057; 09/113,054; 09/112,752; 09/112,759; 09/112,757; 09/112,758; 09/113,107; 09/112,829; 09/112,792; 09/112,791; 09/112,790; 09/112,789; 09/112,788; 09/112,795; 09/112,749; 09/112,784; 09/112,783; 09/112,763; 09/112,762; 09/112,737; 09/112,761; 09/113,223; 09/112,781; 09/113,052; 09/112,834; 09/113,103; 09/113,101; 09/112,751; 09/112,787; 09/112,802; 09/112,803; 09/113,097; 09/113,099; 09/113,084; 09/113,066; 09/112,778; 09/112,779; 09/113,077; 09/113,061; 09/112,818; 09/112,816; 09/112,772; 09/112,819; 09/112,815; 09/113,096; 09/113,068; 09/113,095; 09/112,808; 09/112,809; 09/112,780; 09/113,083; 09/113,121; 09/113,122; 09/112,793; 09/112,794; 09/113,128; 09/113,127; 09/112,756; 09/112,755; 09/112,754; 09/112,811; 09/112,812; 09/112,813; 09/112,814; 09/112,764; 09/112,765; 09/112,767; 09/112,768; 09/112,807; 09/112,806; 09/112,820; 09/112,821; 09/112,822; 09/112,825; 09/112,826; 09/112,827; 09/112,828; 09/113,111; 09/113,108; 09/113,109; 09/113,123; 09/113,114; 09/113,115; 09/113,129; 09/113,124; 09/113,125; 09/113,126; 09/113,119; 09/113,120; 09/113,221; 09/113,116; 09/113,118; 09/113,117; 09/113,113; 09/113,130; 09/113,110; 09/113,112; 09/113,087; 09/113,074; 09/113,089; 09/113,088; 09/112,771; 09/112,769; 09/112,770; 09/112,817; 09/113,076; 09/112,798; 09/112,801; 09/112,800; 09/112,799; 09/113,098; 09/112,833; 09/112,832; 09/112,831; 09/112,830; 09/112,836; 09/112,835; 09/113,102; 09/113,106; 09/113,105; 09/113,104; 09/112,810; 09/112,766; 09/113,085; 09/113,086; 09/113,094; 09/112,760; 09/112,773; 09/112,774; 09/112,775; 09/112,745; 09/113,092; 09/113,100; 09/113,093; 09/113,062; 09/113,064; 09/113,082; 09/113,081; 09/113,080; 09/113,079; 09/113,065; 09/113,078; 09/113,075.[0002]
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
• Not applicable.[0003]
FIELD OF THE INVENTION
• The present invention relates to an image processing method and apparatus and, in particular, discloses a Garment Design and Printing System.[0004]
• The present invention further relates to the creation of fabrics and garments utilising automated apparatuses.[0005]
BACKGROUND OF THE INVENTION
• A number of creative judgements are made when any garment is created. Firstly, there is the shape and styling of the garment and additionally, there is the fabric colours and style. Often, a fashion designer will try many different alternatives and may even attempt to draw the final fashion product before creating the finished garment.[0006]
• Such a process is generally unsatisfactory in providing a rapid and flexible turn around of the garments and also providing rapid judgement of the final appearance of a fashion product on a person.[0007]
SUMMARY OF THE INVENTION
• It is an object of the present invention to provide an alternative form for analysing the look of garments and for their creation. A further object of the present invention is to provide for automatic fabric creation.[0008]
• In accordance with the first aspect of the present invention there is provided A garment creation system comprising:[0009]
• an expected image creation system including an image sensor device and an image display device, said image creation system mapping portions of an arbitrary image sensed by said image sensor device onto a garment and outputting on said display device a depiction of said garment;[0010]
• a garment fabric printer adapted to be interconnected to said image creation system for printing out corresponding pieces of said garment including said mapped portions.[0011]
BRIEF DESCRIPTION OF THE DRAWINGS
• Notwithstanding any other forms which may fall within the scope of the present invention, preferred forms of the invention will now be described, by way of example only, with reference to the accompanying drawings which:[0012]
• FIG. 1 illustrates the basic operation of an Artcam device;[0013]
• FIG. 2 illustrates a series of Artcards for use with the preferred embodiment;[0014]
• FIG. 3 is a flow diagram of the algorithm utilised by the preferred embodiment; and[0015]
• FIG. 4 is a schematic illustration of the outputting of printed fabrics produced in accordance with the present invention.[0016]
DESCRIPTION OF PREFERRED AND OTHER EMBODIMENTS
• The preferred embodiment is preferably implemented through suitable programming of a hand held camera device such as that described in co-pending U.S. patent application Ser. No. 09/113,060 entitled “Digital Instant Printing Camera with Image Processing Capability” (Docket ARTO1) filed concurrently herewith by the present applicant the content of which is hereby specifically incorporated by cross reference.[0017]
• The aforementioned patent specification discloses a camera system, hereinafter known as an “Artcam” type camera, wherein sensed images can be directly printed out by an Artcam portable camera unit. Further, the aforementioned specification discloses means and methods for performing various manipulations on images captured by the camera sensing device leading to the production of various effects in an output image. The manipulations are disclosed to be highly flexible in nature and can be implemented through the insertion into the Artcam of cards having encoded thereon various instructions for the manipulation of images, the cards hereinafter being known as Artcards. The Artcam further has significant onboard processing power provided by an Artcam Central Processor unit (ACP) which is interconnected to a memory device for the storage of important data and images.[0018]
• The aforementioned patent specification discloses an Artcam system as indicated[0019]1 in FIG. 1. The Artcamsystem1 relies on an Artcam2 which takes Artcards3 as an input. The Artcard3 includes encoded information for manipulation of animage scene4 so as to produce an output photo5 which contains substantial manipulation in accordance with the instruction of Artcard3. The Artcards3 are designed to be extremely inexpensive and contain on one surface the encoding information and on the other surface a depiction of the likely effect which will be produced by the Artcard3 when inserted in Artcam2.
• In accordance with the method of the preferred embodiment, as shown in FIG. 2, a large number of Artcards[0020]3 are prepared and distributed inpacks10. Eachpack10 relates to clothing wear of a specific size and includes images eg.11 of models havingclothing apparel12 on to which an image captured by the camera will be mapped. The mapping can be to different items of apparel on different Artcards3. One form of mapping algorithm is as illustrated20 in FIG. 3 wherein theinput image4 is first warped21 utilising a warp map which maps the image to a repeating tiling pattern that produces attractive warping effects. Of course, many other forms of algorithms could be provided for producing an attractive form of material with the algorithm being provided on Artcard3 (FIG. 1).
• Next, a[0021]second warp22 is provided for warping the output offirst warp map21 onto the specific model image in the Artcard. Therefore,warp22 will be Artcard specific. The result can then beoutput23 for printing as an art photo5. Hence, a user is able to point an Artcam2 at adesign image4 and produce art photo5 which has a manipulated version of the image based upon a model's item of fashion apparel or garment. This process can be continued until a desirable result is produced.
• Next, as indicated in FIG. 4, when a final selection has been made, the Artcam[0022]2 can be connected by its USB port, as illustrated at30, to afabric printer34 which can comprise an ink jet fabric printer and associated drive controller electronics etc. Either the Artcam2 or theinkjet printer34 can be programmed to print out onfabric35 the garment pieces eg.36 having on thesurface37 thereof the original warped image so as to produce a garment corresponding to that depicted by the model on the Artcard.
• The output fabric can include tab portions eg.[0023]38 for alignment and border regions eg.39 in addition toinstructions40 for joining the garment pieces together. Preferably, the output program includes providing for warp matching of border regions so as to present a continuous appearance on the garment cross seams. Additionally, a user interface could be provided for utilising the same Artcard with many different output sizes so as to taken into account different shaped bodies. By utilisation of Artcam technology, a system can be provided for customised production of garments and rapid depiction of the likely results by means of utilisation of the Artcamdevice2.
• It would be appreciated by a person skilled in the art that numerous variations and/or modifications may be made to the present invention as shown in the specific embodiment without departing from the spirit or scope of the invention as broadly described. The present embodiment is, therefore, to be considered in all respects to be illustrative and not restrictive.[0024]
• Ink Jet Technologies[0025]
• The embodiments of the invention use an ink jet printer type device. Of course many different devices could be used. However presently popular ink jet printing technologies are unlikely to be suitable.[0026]
• The most significant problem with thermal ink jet is power consumption. This is approximately 100 times that required for high speed, and stems from the energy-inefficient means of drop ejection. This involves the rapid boiling of water to produce a vapor bubble which expels the ink. Water has a very high heat capacity, and must be superheated in thermal ink jet applications. This leads to an efficiency of around 0.02%, from electricity input to drop momentum (and increased surface area) out.[0027]
• The most significant problem with piezoelectric ink jet is size and cost. Piezoelectric crystals have a very small deflection at reasonable drive voltages, and therefore require a large area for each nozzle. Also, each piezoelectric actuator must be connected to its drive circuit on a separate substrate. This is not a significant problem at the current limit of around 300 nozzles per print head, but is a major impediment to the fabrication of pagewidth print heads with 19,200 nozzles.[0028]
• Ideally, the ink jet technologies used meet the stringent requirements of in-camera digital color printing and other high quality, high speed, low cost printing applications. To meet the requirements of digital photography, new inkjet technologies have been created. The target features include:[0029]
• low power (less than 10 Watts)[0030]
• high resolution capability (1,600 dpi or more)[0031]
• photographic quality output[0032]
• low manufacturing cost[0033]
• small size (pagewidth times minimum cross section)[0034]
• high speed (<2 seconds per page).[0035]
• All of these features can be met or exceeded by the ink jet systems described below with differing levels of difficulty. Forty-five different ink jet technologies have been developed by the Assignee to give a wide range of choices for high volume manufacture. These technologies form part of separate applications assigned to the present Assignee as set out in the list under the heading Cross References to Related Applications.[0036]
• The ink jet designs shown here are suitable for a wide range of digital printing systems, from battery powered one-time use digital cameras, through to desktop and network printers, and through to commercial printing systems[0037]
• For ease of manufacture using standard process equipment, the print head is designed to be a monolithic 0.5 micron CMOS chip with MEMS post processing. For color photographic applications, the print head is 100 mm long, with a width which depends upon the ink jet type. The smallest print head designed is covered in U.S. patent application Ser. No. 09/112,764, which is 0.35 mm wide, giving a chip area of 35 square mm. The print heads each contain 19,200 nozzles plus data and control circuitry.[0038]
• Ink is supplied to the back of the print head by injection molded plastic ink channels. The molding requires 50 micron features, which can be created using a lithographically micromachined insert in a standard injection molding tool. Ink flows through holes etched through the wafer to the nozzle chambers fabricated on the front surface of the wafer. The print head is connected to the camera circuitry by tape automated bonding.[0039]
• Tables of Drop-on-Demand Ink Jets[0040]
• The present invention is useful in the field of digital printing, in particular, ink jet printing. A number of patent applications in this field were filed simultaneously and incorporated by cross reference.[0041]
• Eleven important characteristics of the fundamental operation of individual ink jet nozzles have been identified. These characteristics are largely orthogonal, and so can be elucidated as an eleven dimensional matrix. Most of the eleven axes of this matrix include entries developed by the present assignee.[0042]
• The following tables form the axes of an eleven dimensional table of ink jet types.[0043]
• Actuator mechanism (18 types)[0044]
• Basic operation mode (7 types)[0045]
• Auxiliary mechanism (8 types)[0046]
• Actuator amplification or modification method (17 types)[0047]
• Actuator motion (19 types)[0048]
• Nozzle refill method (4 types)[0049]
• Method of restricting back-flow through inlet (10 types)[0050]
• Nozzle clearing method (9 types)[0051]
• Nozzle plate construction (9 types)[0052]
• Drop ejection direction (5 types)[0053]
• Ink type (7 types)[0054]
• The complete eleven dimensional table represented by these axes contains 36.9 billion possible configurations of inkjet nozzle. While not all of the possible combinations result in a viable ink jet technology, many million configurations are viable. It is clearly impractical to elucidate all of the possible configurations. Instead, certain ink jet types have been investigated in detail. Forty-five such inkjet types were filed simultaneously to the present application.[0055]
• Other ink jet configurations can readily be derived from these forty-five examples by substituting alternative configurations along one or more of the 11 axes. Most of the forty-five examples can be made into ink jet print heads with characteristics superior to any currently available ink jet technology.[0056]
• Where there are prior art examples known to the inventor, one or more of these examples are listed in the examples column of the tables below. The simultaneously filed patent applications by the present applicant are listed by USSN numbers. In some cases, a print technology may be listed more than once in a table, where it shares characteristics with more than one entry.[0057]
• Suitable applications for the ink jet technologies include: Home printers, Office network printers, Short run digital printers, Commercial print systems, Fabric printers, Pocket printers, Internet WWW printers, Video printers, Medical imaging, Wide format printers, Notebook PC printers, Fax machines, Industrial printing systems, Photocopiers, Photographic minilabs etc.[0058]
• The information associated with the aforementioned 11 dimensional matrix are set out in the following tables.[0059]

  ACTUATOR MECHANISM (APPLIED ONLY TO SELECTED INK DROPS)

  	Description	Advantages	Disadvantages	Examples

  Thermal	An electrothermal	Large force	High power	Canon Bubblejet 1979
  bubble	heater heats the ink	generated	Ink carrier limited	Endo et al GB patent
  	to above boiling	Simple	to water	2,007,162
  	point, transferring	construction	Low efficiency	Xerox heater-in-pit
  	significant heat to	No moving	High temperatures	1990 Hawkins et al
  	the aqueous ink. A	parts	required	USP 4,899,181
  	bubble nucleates	Fast operation	High mechanical	Hewlett-Packard TIJ
  	and quickly forms,	Small chip area	stress	1982 Vaught et al USP
  	expelling the ink.	required for	Unusual materials	4,490,728
  	The efficiency of the	actuator	required
  	process is low, with		Large drive
  	typically less than		transistors
  	0.05% of the		Cavitation causes
  	electrical energy		actuator failure
  	being transformed		Kogation reduces
  	into kinetic energy		bubble formation
  	of the drop.		Large print heads
  			are difficult to
  			fabricate
  Piezo-	A piezoelectric	Low power	Very large area	Kyser et al USP
  electric	crystal such as lead	consumption	required for	3,946,398
  	lanthanum zirconate	Many ink types	actuator	Zoltan USP 3,683,212
  	(PZT) is electrically	can be used	Difficult to	1973 Stemme USP
  	activated, and either	Fast operation	integrate with	3,747,120
  	expands, shears, or	High efficiency	electronics	Epson Stylus
  	bends to apply		High voltage drive	Tektronix
  	pressure to the ink,		transistors	USSN 09/112,803
  	ejecting drops.		required
  			Full pagewidth
  			print heads
  			impractical due to
  			actuator size
  			Requires electrical
  			poling in high
  			field strengths
  			during
  			manufacture
  Electro-	An electric field is	Low power	Low maximum	Seiko Epson, Usui et all
  strictive	used to activate	consumption	strain (approx.	JP 253401/96
  	electrostriction in	Many ink types	0.01%)	USSN 09/112,803
  	relaxor materials	can be used	Large area
  	such as lead	Low thermal	required for
  	lanthanum zirconate	expansion	actuator due to
  	titanate (PLZT) or	Electric field	low strain
  	lead magnesium	strength	Response speed is
  	niobate (PMN).	required	marginal (˜10 μs)
  		(approx. 3.5	High voltage drive
  		V/μm) can be	transistors
  		generated	required
  		without	Full pagewidth
  		difficulty	print heads
  		Does not	impractical due to
  		require	actuator size
  		electrical poling
  Ferro-	An electric field is	Low power	Difficult to	USSN 09/112,803
  electric	used to induce a	consumption	integrate with
  	phase transition	Many ink types	electronics
  	between the	can be used	Unusual materials
  	antiferroelectric	Fast operation	such as PLZSnT
  	(AFE) and	(<1 μs)	are required
  	ferroelectric (FE)	Relatively high	Actuators require
  	phase. Perovskite	longitudinal	a large area
  	materials such as tin	strain
  	modified lead	High efficiency
  	lanthanum zirconate	Electric field
  	titanate (PLZSnT)	strength of
  	exhibit large strains	around 3 V/μm
  	of up to 1%	can be readily
  	associated with the	provided
  	AFE to FE phase
  	transition.
  Electro-	Conductive plates	Low power	Difficult to	USSN 09/112,787;
  static	are separated by a	consumption	operate	09/112,803
  plates	compressible or	Many ink types	electrostatic
  	fluid dielectric	can be used	devices in an
  	(usually air). Upon	Fast operation	aqueous
  	application of a		environment
  	voltage, the plates		The electrostatic
  	attract each other		actuator will
  	and displace ink,		normally need to
  	causing drop		be separated from
  	ejection. The		the ink
  	conductive plates		Very large area
  	may be in a comb or		required to
  	honeycomb		achieve high
  	structure, or stacked		forces
  	to increase the		High voltage drive
  	surface area and		transistors may be
  	therefore the force.		required
  			Full pagewidth
  			print heads are not
  			competitive due to
  			actuator size
  Electro-	A strong electric	Low current	High voltage	1989 Saito et al, USP
  static pull	field is applied to	consumption	required	4,799,068
  on ink	the ink, whereupon	Low	May be damaged	1989 Miura et al, USP
  	electrostatic	temperature	by sparks due to	4,810,954
  	attraction		air breakdown	Tone-jet
  	accelerates the ink		Required field
  	towards the print		strength increases
  	medium.		as the drop size
  			decreases
  			High voltage drive
  			transistors
  			required
  			Electrostatic field
  			attracts dust
  Permanent	An electromagnet	Low power	Complex	USSN 09/113,084;
  magnet	directly attracts a	consumption	fabrication	09/112,779
  electro-	permanent magnet,	Many ink types	Permanent
  magnetic	displacing ink and	can be used	magnetic material
  	causing drop	Fast operation	such as
  	ejection. Rare earth	High efficiency	Neodymium Iron
  	magnets with a field	Easy extension	Boron (NdFeB)
  	strength around 1	from single	required.
  	Tesla can be used.	nozzles to	High local
  	Examples are:	pagewidth print	currents required
  	Samarium Cobalt	heads	Copper
  	(SaCo) and		metalization
  	magnetic materials		should be used for
  	in the neodymium		long
  	iron boron family		electromigration
  	(NdFeB,		lifetime and low
  	NdDyFeBNb,		resistivity
  	NdDyFeB, etc)		Pigmented inks
  			are usually
  			infeasible
  			Operating
  			temperature
  			limited to the
  			Curie temperature
  			(around 540 K)
  Soft	A solenoid induced	Low power	Complex	USSN 09/112,751;
  magnetic	a magnetic field in a	consumption	fabrication	09/113,097; 09/113,066;
  core	soft magnetic core	Many ink types	Materials not	09/112,779; 09/113,061;
  electro-	or yoke fabricated	can be used	usually present in	09/112,816; 09/112,772;
  magnetic	from a ferrous	Fast operation	a CMOS fab such	09/112,815
  	material such as	High efficiency	as NiFe, CoNiFe,
  	electroplated iron	Easy extension	or CoFe are
  	alloys such as	from single	required
  	CoNiFe [1], CoFe,	nozzles to	High local
  	or NiFe alloys.	pagewidth print	currents required
  	Typically, the soft	heads	Copper
  	magnetic material is		metalization
  	in two parts, which		should be used for
  	are normally held		long
  	apart by a spring.		electromigration
  	When the solenoid		lifetime and low
  	is actuated, the two		resistivity
  	parts attract,		Electroplating is
  	displacing the ink.		required
  			High saturation
  			flux density is
  			required (2.0-2.1
  			T is achievable
  			with CoNiFe [1])
  Lorenz	The Lorenz force	Low power	Force acts as a	USSN 09/113,099;
  force	acting on a current	consumption	twisting motion	09/113,077; 09/112,818;
  	carrying wire in a	Many ink types	Typically, only a	09/112,819
  	magnetic field is	can be used	quarter of the
  	utilized.	Fast operation	solenoid length
  	This allows the	High efficiency	provides force in a
  	magnetic field to be	Easy extension	useful direction
  	supplied externally	from single	High local
  	to the print head, for	nozzles to	currents required
  	example with rare	pagewidth print	Copper
  	earth permanent	heads	metalization
  	magnets.		should be used for
  	Only the current		long
  	carrying wire need		electromigration
  	be fabricated on the		lifetime and low
  	print-head,		resistivity
  	simplifying		Pigmented inks
  	materials		are usually
  	requirements.		infeasible
  Magneto-	The actuator uses	Many ink types	Force acts as a	Fischenbeck, USP
  striction	the giant	can be used	twisting motion	4,032,929
  	magnetostrictive	Fast operation	Unusual materials	USSN 09/113,121
  	effect of materials	Easy extension	such as Terfenol-
  	such as Terfenol-D	from single	D are required
  	(an alloy of terbium,	nozzles to	High local
  	dysprosium and iron	pagewidth print	currents required
  	developed at the	heads	Copper
  	Naval Ordnance	High force is	metalization
  	Laboratory, hence	available	should be used for
  	Ter-Fe-NOL). For		long
  	best efficiency, the		electromigration
  	actuator should be		lifetime and low
  	pre-stressed to		resistivity
  	approx. 8 MPa.		Pre-stressing may
  			be required
  Surface	Ink under positive	Low power	Requires	Silverbrook, EP 0771
  tension	pressure is held in a	consumption	supplementary	658 A2 and related
  reduction	nozzle by surface	Simple	force to effect	patent applications
  	tension. The surface	construction	drop separation
  	tension of the ink is	No unusual	Requires special
  	reduced below the	materials	ink surfactants
  	bubble threshold,	required in	Speed may be
  	causing the ink to	fabrication	limited by
  	egress from the	High efficiency	surfactant
  	nozzle.	Easy extension	properties
  		from single
  		nozzles to
  		pagewidth print
  		heads
  Viscosity	The ink viscosity is	Simple	Requires	Silverbrook, EP 0771
  reduction	locally reduced to	construction	supplementary	658 A2 and related
  	select which drops	No unusual	force to effect	patent applications
  	are to be ejected. A	materials	drop separation
  	viscosity reduction	required in	Requires special
  	can be achieved	fabrication	ink viscosity
  	electrothermally	Easy extension	properties
  	with most inks, but	from single	High speed is
  	special inks can be	nozzles to	difficult to achieve
  	engineered for a	pagewidth print	Requires
  	100:1 viscosity	heads	oscillating ink
  	reduction.		pressure
  			A high
  			temperature
  			difference
  			(typically 80
  			degrees) is
  			required
  Acoustic	An acoustic wave is	Can operate	Complex drive	1993 Hadimioglu et al,
  	generated and	without a nozzle	circuitry	EUP 550,192
  	focussed upon the	plate	Complex	1993 Elrod et al, EUP
  	drop ejection region.		fabrication	572,220
  			Low efficiency
  			Poor control of
  			drop position
  			Poor control of
  			drop volume
  Thermo-	An actuator which	Low power	Efficient aqueous	USSN 09/112,802;
  elastic	relies upon	consumption	operation requires	09/112,778; 09/112,815;
  bend	differential thermal	Many ink types	a thermal insulator	09/113,096; 09/113,068;
  actuator	expansion upon	can be used	on the hot side	09/113,095; 09/112,808;
  	Joule heating is	Simple planar	Corrosion	09/112,809; 09/112,780;
  	used.	fabrication	prevention can be	09/113,083; 09/112,793;
  		Small chip area	difficult	09/112,794; 09/113,128;
  		required for	Pigmented inks	09/113,127; 09/112,756;
  		each actuator	may be infeasible,	09/112,755; 09/112,754;
  		Fast operation	as pigment	09/112,811; 09/112,812;
  		High efficiency	particles may jam	09/112,813; 09/112,814;
  		CMOS	the bend actuator	09/112,764; 09/112,765;
  		compatible		09/112,767; 09/112,768
  		voltages and
  		currents
  		Standard
  		MEMS
  		processes can
  		be used
  		Easy extension
  		from single
  		nozzles to
  		pagewidth print
  		heads
  High CTE	A material with a	High force can	Requires special	USSN 09/112,778;
  thermo-	very high coefficient	be generated	material (e.g.	09/112,815; 09/113,096;
  elastic	of thermal	Three methods	PTFE)	09/113,095; 09/112,808;
  actuator	expansion (CTE)	of PTFE	Requires a PTFE	09/112,809; 09/112,780;
  	such as	deposition are	deposition	09/113,083; 09/112,793;
  	polytetrafluoroethyl-	under	process, which is	09/112,794; 09/113,128;
  	ene (PTFE) is used.	development:	not yet standard in	09/113,127; 09/112,756;
  	As high CTE	chemical vapor	ULSI fabs	09/112,807; 09/112,806;
  	materials are usually	deposition	PTFE deposition	09/112,820
  	non-conductive, a	(CVD), spin	cannot be
  	heater fabricated	coating, and	followed with
  	from a conductive	evaporation	high temperature
  	material is	PTFE is a	(above 350° C.)
  	incorporated. A 50	candidate for	processing
  	μm long PTFE bend	low dielectric	Pigmented inks
  	actuator with	constant	may be infeasible,
  	polysilicon heater	insulation in	as pigment
  	and 15 mW power	ULSI	particles may jam
  	input can provide	Very low power	the bend actuator
  	180 μN force and 10	consumption
  	μm deflection.	Many ink types
  	Actuator motions	can be used
  	include:	Simple planar
  	Bend	fabrication
  	Push	Small chip area
  	Buckle	required for
  	Rotate	each actuator
  		Fast operation
  		High efficiency
  		CMOS
  		compatible
  		voltages and
  		currents
  		Easy extension
  		from single
  		nozzles to
  		pagewidth print
  		heads
  Conduct-	A polymer with a	High force can	Requires special	USSN 09/113,083
  ive	high coefficient of	be generated	materials
  polymer	thermal expansion	Very low power	development
  thermo-	(such as PTFE) is	consumption	(High CTE
  elastic	doped with	Many ink types	conductive
  actuator	conducting	can be used	polymer)
  	substances to	Simple planar	Requires a PTFE
  	increase its	fabrication	deposition
  	conductivity to	Small chip area	process, which is
  	about 3 orders of	required for	not yet standard in
  	magnitude below	each actuator	ULSI fabs
  	that of copper. The	Fast operation	PTFE deposition
  	conducting polymer	High efficiency	cannot be
  	expands when	CMOS	followed with
  	resistively heated.	compatible	high temperature
  	Examples of	voltages and	(above 350° C.)
  	conducting dopants	currents	processing
  	include:	Easy extension	Evaporation and
  	Carbon nanotubes	from single	CVD deposition
  	Metal fibers	nozzles to	techniques cannot
  	Conductive	pagewidth print	be used
  	polymers such as	heads	Pigmented inks
  	doped		may be infeasible,
  	polythiophene		as pigment
  	Carbon granules		particles may jam
  			the bend actuator
  Shape	A shape memory	High force is	Fatigue limits	USSN 09/113,122
  memory	alloy such as TiNi	available	maximum number
  alloy	(also known as	(stresses of	of cycles
  	Nitinol-Nickel	hundreds of	Low strain (1%) is
  	Titanium alloy	MPa)	required to extend
  	developed at the	Large strain is	fatigue resistance
  	Naval Ordnance	available (more	Cycle rate limited
  	Laboratory) is	than 3%)	by heat removal
  	thermally switched	High corrosion	Requires unusual
  	between its weak	resistance	materials (TiNi)
  	martensitic state and	Simple	The latent heat of
  	its high stiffness	construction	transformation
  	austenic state. The	Easy extension	must be provided
  	shape of the actuator	from single	High current
  	in its martensitic	nozzles to	operation
  	state is deformed	pagewidth print	Requires pre-
  	relative to the	heads	stressing to distort
  	austenic shape. The	Low voltage	the martensitic
  	shape change causes	operation	state
  	ejection of a drop.
  Linear	Linear magnetic	Linear Magnetic	Requires unusual	USSN 09/113,061
  Magnetic	actuators include the	actuators can be	semiconductor
  Actuator	Linear Induction	constructed with	materials such as
  	Actuator (LIA),	high thrust, long	soft magnetic
  	Linear Permanent	travel, and high	alloys (e.g.
  	Magnet	efficiency using	CoNiFe)
  	Synchronous	planar	Some varieties
  	Actuator (LPMSA),	semiconductor	also require
  	Linear Reluctance	fabrication	permanent
  	Synchronous	techniques	magnetic
  	Actuator (LRSA),	Long actuator	materials such as
  	Linear Switched	travel is	Neodymium iron
  	Reluctance Actuator	available	boron (NdFeB)
  	(LSRA), and the	Medium force is	Requires complex
  	Linear Stepper	available	multi-phase drive
  	Actuator (LSA).	Low voltage	circuitry
  		operation	High current
  			operation

• [0060]

  BASIC OPERATION MODE

  	Description	Advantages	Disadvantages	Examples

  Actuator	This is the simplest	Simple	Drop repetition	Thermal ink jet
  directly	mode of operation:	operation	rate is usually	Piezoelectric ink jet
  pushes ink	the actuator directly	No external	limited to around	USSN 09/112,751;
  	supplies sufficient	fields required	10 kHz.	09/112,787; 09/112,802;
  	kinetic energy to	Satellite drops	However, this is	09/112,803; 09/113,097;
  	expel the drop. The	can be avoided	not fundamental	09/113,099; 09/113,084;
  	drop must have a	if drop velocity	to the method,	09/112,778; 09/113,077;
  	sufficient velocity to	is less than 4	but is related to	09/113,061; 09/112,816;
  	overcome the	m/s	the refill method	09/112,819; 09/113,095;
  	surface tension.	Can be efficient,	normally used	09/112,809; 09/112,780;
  		depending upon	All of the drop	09/113,083; 09/113,121;
  		the actuator	kinetic energy	09/113,122; 09/112,793;
  		used	must be provided	09/112,794; 09/113,128;
  			by the actuator	09/113,127; 09/112,756;
  			Satellite drops	09/112,755; 09/112,754;
  			usually form if	09/112,811; 09/112,812;
  			drop velocity is	09/112,813; 09/112,814;
  			greater than 4.5	09/112,764; 09/112,765;
  			m/s	09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820
  Proximity	The drops to be	Very simple	Requires close	Silverbrook, EP 0771
  	printed are selected	print head	proximity	658 A2 and related
  	by some manner	fabrication can	between the print	patent applications
  	(e.g. thermally	be used	head and the
  	induced surface	The drop	print media or
  	tension reduction of	selection means	transfer roller
  	pressurized ink).	does not need to	May require two
  	Selected drops are	provide the	print heads
  	separated from the	energy required	printing alternate
  	ink in the nozzle by	to separate the	rows of the
  	contact with the	drop from the	image
  	print medium or a	nozzle	Monolithic color
  	transfer roller.		print heads are
  			difficult
  Electro-	The drops to be	Very simple	Requires very	Silverbrook, EP 0771
  static pull	printed are selected	print head	high electrostatic	658 A2 and related
  on ink	by some manner	fabrication can	field	patent applications
  	(e.g. thermally	be used	Electrostatic field	Tone-Jet
  	induced surface	The drop	for small nozzle
  	tension reduction of	selection means	sizes is above air
  	pressurized ink).	does not need to	breakdown
  	Selected drops are	provide the	Electrostatic field
  	separated from the	energy required	may attract dust
  	ink in the nozzle by	to separate the
  	a strong electric	drop from the
  	field.	nozzle
  Magnetic	The drops to be	Very simple	Requires	Silverbrook, EP 0771
  pull on ink	printed are selected	print head	magnetic ink	658 A2 and related
  	by some manner	fabrication can	Ink colors other	patent applications
  	(e.g. thermally	be used	than black are
  	induced surface	The drop	difficult
  	tension reduction of	selection means	Requires very
  	pressurized ink).	does not need to	high magnetic
  	Selected drops are	provide the	fields
  	separated from the	energy required
  	ink in the nozzle by	to separate the
  	a strong magnetic	drop from the
  	field acting on the	nozzle
  	magnetic ink.
  Shutter	The actuator moves	High speed	Moving parts are	USSN 09/112,818;
  	a shutter to block	(>50 kHz)	required	09/112,815; 09/112,808
  	ink flow to the	operation can be	Requires ink
  	nozzle. The ink	achieved due to	pressure
  	pressure is pulsed at	reduced refill	modulator
  	a multiple of the	time	Friction and wear
  	drop ejection	Drop timing can	must be
  	frequency.	be very accurate	considered
  		The actuator	Stiction is
  		energy can be	possible
  		very low
  Shuttered	The actuator moves	Actuators with	Moving parts are	USSN 09/113,066;
  grill	a shutter to block	small travel can	required	09/112,772; 09/113,096;
  	ink flow through a	be used	Requires ink	09/113,068
  	grill to the nozzle.	Actuators with	pressure
  	The shutter	small force can	modulator
  	movement need	be used	Friction and wear
  	only be equal to the	High speed	must be
  	width of the grill	(>50 kHz)	considered
  	holes.	operation can be	Stiction is
  		achieved	possible
  Pulsed	A pulsed magnetic	Extremely low	Requires an	USSN 09/112,779
  magnetic	field attracts an ‘ink	energy	external pulsed
  pull on ink	pusher’ at the drop	operation is	magnetic field
  pusher	ejection frequency.	possible	Requires special
  	An actuator controls	No heat	materials for both
  	a catch, which	dissipation	the actuator and
  	prevents the ink	problems	the ink pusher
  	pusher from moving		Complex
  	when a drop is not		construction
  	to be ejected.

• [0061]

  AUXILIARY MECHANISM (APPLIED TO ALL NOZZLES)

  	Description	Advantages	Disadvantages	Examples

  None	The actuator directly	Simplicity of	Drop ejection	Most ink jets, including
  	fires the ink drop,	construction	energy must be	piezoelectric and thermal
  	and there is no	Simplicity of	supplied by	bubble.
  	external field or	operation	individual nozzle	USSN 09/112,751;
  	other mechanism	Small physical	actuator	09/112,787; 09/112,802;
  	required.	size		09/112,803; 09/113,097;
  				09/113,084; 09/113,078;
  				09/113,077; 09/113,061;
  				09/112,816; 09/113,095;
  				09/112,809; 09/112,780;
  				09/113,083; 09/113,121;
  				09/113,122; 09/112,793;
  				09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820
  Oscillating	The ink pressure	Oscillating ink	Requires external	Silverbrook, EP 0771
  ink	oscillates, providing	pressure can	ink pressure	658 A2 and related
  pressure	much of the drop	provide a refill	oscillator	patent applications
  (including	ejection energy. The	pulse, allowing	Ink pressure	USSN 09/113,066;
  acoustic	actuator selects	higher operating	phase and	09/112,818; 09/112,772;
  stimula-	which drops are to	speed	amplitude must	09/112,815; 09/113,096;
  tion)	be fired by	The actuators	be carefully	09/113,068; 09/112,808
  	selectively blocking	may operate	controlled
  	or enabling nozzles.	with much	Acoustic
  	The ink pressure	lower energy	reflections in the
  	oscillation may be	Acoustic lenses	ink chamber
  	achieved by	can be used to	must be designed
  	vibrating the print	focus the sound	for
  	head, or preferably	on the nozzles
  	by an actuator in the
  	ink supply.
  Media	The print head is	Low power	Precision	Silverbrook, EP 0771
  proximity	placed in close	High accuracy	assembly	658 A2 and related
  	proximity to the	Simple print	required	patent applications
  	print medium.	head	Paper fibers may
  	Selected drops	construction	cause problems
  	protrude from the		Cannot print on
  	print head further		rough substrates
  	than unselected
  	drops, and contact
  	the print medium.
  	The drop soaks into
  	the medium fast
  	enough to cause
  	drop separation.
  Transfer	Drops are printed to	High accuracy	Bulky	Silverbrook, EP 0771
  roller	a transfer roller	Wide range of	Expensive	658 A2 and related
  	instead of straight to	print substrates	Complex	patent applications
  	the print medium. A	can be used	construction	Tektronix hot melt
  	transfer roller can	Ink can be dried		piezoelectric ink jet
  	also be used for	on the transfer		Any of USSN
  	proximity drop	roller		09/112,751; 09/112,787;
  	separation.			09/112,802; 09/112,803;
  				09/113,097; 09/113,099;
  				09/113,084; 09/113,066;
  				09/112,778; 09/112,779;
  				09/113,077; 09/113,061;
  				09/112,818; 09/112,816;
  				09/112,772; 09/112,819;
  				09/112,815; 09/113,096;
  				09/113,068; 09/113,095;
  				09/112,808; 09/112,809;
  				09/112,780; 09/113,083;
  				09/113,121; 09/113,122;
  				09/112,793; 09/112,794;
  				09/113,128; 09/113,127;
  				09/112,756; 09/112,755;
  				09/112,754; 09/112,811;
  				09/112,812; 09/112,813;
  				09/112,814; 09/112,764;
  				09/112,765; 09/112,767;
  				09/112,768; 09/112,807;
  				09/112,806; 09/112,820;
  				09/112,821
  Electro-	An electric field is	Low power	Field strength	Silverbrook, EP 0771
  static	used to accelerate	Simple print	required for	658 A2 and related
  	selected drops	head	separation of	patent applications
  	towards the print	construction	small drops is	Tone-Jet
  	medium.		near or above air
  			breakdown
  Direct	A magnetic field is	Low power	Requires	Silverbrook, EP 0771
  magnetic	used to accelerate	Simple print	magnetic ink	658 A2 and related
  field	selected drops of	head	Requires strong	patent applications
  	magnetic ink	construction	magnetic field
  	towards the print
  	medium.
  Cross	The print head is	Does not	Requires external	USSN 09/113,099;
  magnetic	placed in a constant	require	magnet	09/112,819
  field	magnetic field. The	magnetic	Current densities
  	Lorenz force in a	materials to be	may be high,
  	current carrying	integrated in the	resulting in
  	wire is used to move	print head	electromigration
  	the actuator.	manufacturing	problems
  		process
  Pulsed	A pulsed magnetic	Very low power	Complex print	USSN 09/112,779
  magnetic	field is used to	operation is	head construction
  field	cyclically attract a	possible	Magnetic
  	paddle, which	Small print head	materials
  	pushes on the ink. A	size	required in print
  	small actuator		head
  	moves a catch,
  	which selectively
  	prevents the paddle
  	from moving.

• [0062]

  	Description	Advantages	Disadvantages	Examples

  ACTUATOR AMPLIFICATION OR MODIFICATION METHOD

  None	No actuator	Operational	Many actuator	Thermal Bubble Ink jet
  	mechanical	simplicity	mechanisms	USSN 09/112,751;
  	amplification is		have	09/112,787; 09/113,099;
  	used. The actuator		insufficient	09/113,084; 09/112,819;
  	directly drives the		travel, or	09/113,121; 09/113,122
  	drop ejection		insufficient
  	process.		force, to
  			efficiently drive
  			the drop
  			ejection process
  Differential	An actuator material	Provides greater	High stresses	Piezoelectric
  expansion	expands more on	travel in a	are involved	USSN 09/112,802;
  bend	one side than on the	reduced print	Care must be	09/112,778; 09/112,815;
  actuator	other. The	head area	taken that the	09/113,096; 09/113,068;
  	expansion may be		materials do not	09/113,095; 09/112,808;
  	thermal,		delaminate	09/112,809; 09/112,780;
  	piezoelectric,		Residual bend	09/113,083; 09/112,793;
  	magnetostrictive, or		resulting from	09/113,128; 09/113,127;
  	other mechanism.		high	09/112,756; 09/112,755;
  	The bend actuator		temperature or	09/112,754; 09/112,811;
  	converts a high		high stress	09/112,812; 09/112,813;
  	force low travel		during	09/112,814; 09/112,764;
  	actuator mechanism		formation	09/112,765; 09/112,767;
  	to high travel, lower			09/112,768; 09/112,807;
  	force mechanism.			09/112,806; 09/112,820
  Transient	A trilayer bend	Very good	High stresses	USSN 09/112,767;
  bend	actuator where the	temperature	are involved	09/112,768
  actuator	two outside layers	stability	Care must be
  	are identical. This	High speed, as a	taken that the
  	cancels bend due to	new drop can be	materials do not
  	ambient temperature	fired before heat	delaminate
  	and residual stress.	dissipates
  	The actuator only	Cancels residual
  	responds to transient	stress of
  	heating of one side	formation
  	or the other.
  Reverse	The actuator loads a	Better coupling	Fabrication	USSN 09/113,097;
  spring	spring. When the	to the ink	complexity	09/113,077
  	actuator is turned		High stress in
  	off, the spring		the spring
  	releases. This can
  	reverse the
  	force/distance curve
  	of the actuator to
  	make it compatible
  	with the force/time
  	requirements of the
  	drop ejection.
  Actuator	A series of thin	Increased travel	Increased	Some piezoelectric ink
  stack	actuators are	Reduced drive	fabrication	jets
  	stacked. This can be	voltage	complexity	USSN 09/112,803
  	appropriate where		Increased
  	actuators require		possibility of
  	high electric field		short circuits
  	strength, such as		due to pinholes
  	electrostatic and
  	piezoelectric
  	actuators.
  Multiple	Multiple smaller	Increases the	Actuator forces	USSN 09/113,061;
  actuators	actuators are used	force available	may not add	09/112,818; 09/113,096;
  	simultaneously to	from an actuator	linearly,	09/113,095; 09/112,809;
  	move the ink. Each	Multiple	reducing	09/112,794; 09/112,807;
  	actuator need	actuators can be	efficiency	09/112,806
  	provide only a	positioned to
  	portion of the force	control ink flow
  	required.	accurately
  Linear	A linear spring is	Matches low	Requires print	USSN 09/112,772
  Spring	used to transform a	travel actuator	head area for
  	motion with small	with higher	the spring
  	travel and high force	travel
  	into a longer travel,	requirements
  	lower force motion.	Non-contact
  		method of
  		motion
  		transformation
  Coiled	A bend actuator is	Increases travel	Generally	USSN 09/112,815;
  actuator	coiled to provide	Reduces chip	restricted to	09/112,808; 09/112,811;
  	greater travel in a	area	planar	09/112,812
  	reduced chip area.	Planar	implementations
  		implementations	due to extreme
  		are relatively	fabrication
  		easy to	difficulty in
  		fabricate.	other
  			orientations.
  Flexure	A bend actuator has	Simple means	Care must be	USSN 09/112,779;
  bend	a small region near	of increasing	taken not to	09/113,068; 09/112,754
  actuator	the fixture point,	travel of a bend	exceed the
  	which flexes much	actuator	elastic limit in
  	more readily than		the flexure area
  	the remainder of the		Stress
  	actuator. The		distribution is
  	actuator flexing is		very uneven
  	effectively		Difficult to
  	converted from an		accurately
  	even coiling to an		model with
  	angular bend,		finite element
  	resulting in greater		analysis
  	travel of the actuator
  	tip.
  Catch	The actuator	Very low	Complex	USSN 09/112,779
  	controls a small	actuator energy	construction
  	catch. The catch	Very small	Requires
  	either enables or	actuator size	external force
  	disables movement		Unsuitable for
  	of an ink pusher that		pigmented inks
  	is controlled in a
  	bulk manner.
  Gears	Gears can be used to	Low force, low	Moving parts	USSN 09/112,818
  	increase travel at the	travel actuators	are required
  	expense of duration.	can be used	Several actuator
  	Circular gears, rack	Can be	cycles are
  	and pinion, ratchets,	fabricated using	required
  	and other gearing	standard surface	More complex
  	methods can be	MEMS	drive electronics
  	used.	processes	Complex
  			construction
  			Friction,
  			friction, and
  			wear are
  			possible
  Buckle	A buckle plate can	Very fast	Must stay	S. Hirata et al, “An Ink-jet
  plate	be used to change a	movement	within elastic	Head Using Diaphragm
  	slow actuator into a	achievable	limits of the	Microactuator”, Proc.
  	fast motion. It can		materials for	IEEE MEMS, Feb. 1996,
  	also convert a high		long device life	pp 418-423.
  	force, low travel		High stresses	USSN 09/113,096;
  	actuator into a high		involved	09/112,793
  	travel, medium force		Generally high
  	motion.		power
  			requirement
  Tapered	A tapered magnetic	Linearizes the	Complex	USSN 09/112,816
  magnetic	pole can increase	magnetic	construction
  pole	travel at the expense	force/distance
  	of force.	curve
  Lever	A lever and fulcrum	Matches low	High stress	USSN 09/112,755;
  	is used to transform	travel actuator	around the	09/112,813; 09/112,814
  	a motion with small	with higher	fulcrum
  	travel and high force	travel
  	into a motion with	requirements
  	longer travel and	Fulcrum area
  	lower force. The	has no linear
  	lever can also	movement, and
  	reverse the direction	can be used for
  	of travel.	a fluid seal
  Rotary	The actuator is	High	Complex	USSN 09/112,794
  impeller	connected to a	mechanical	construction
  	rotary impeller. A	advantage	Unsuitable for
  	small angular	The ratio of	pigmented inks
  	deflection of the	force to travel
  	actuator results in a	of the actuator
  	rotation of the	can be matched
  	impeller vanes,	to the nozzle
  	which push the ink	requirements by
  	against stationary	varying the
  	vanes and out of the	number of
  	nozzle.	impeller vanes
  Acoustic	A refractive or	No moving	Large area	1993 Hadimioglu et al,
  lens	diffractive (e.g. zone	parts	required	EUP 550,192
  	plate) acoustic lens		Only relevant	1993 Elrod et al, EUP
  	is used to		for acoustic ink	572,220
  	concentrate sound		jets
  	waves.
  Sharp	A sharp point is	Simple	Difficult to	Tone-jet
  conductive	used to concentrate	construction	fabricate using
  point	an electrostatic field.		standard VLSI
  			processes for a
  			surface ejecting
  			ink-jet
  			Only relevant
  			for electrostatic
  			ink jets

  ACTUATOR MOTION

  Volume	The volume of the	Simple	High energy is	Hewlett-Packard Thermal
  expansion	actuator changes,	construction in	typically	Ink jet
  	pushing the ink in	the case of	required to	Canon Bubblejet
  	all directions.	thermal ink jet	achieve volume
  			expansion. This
  			leads to thermal
  			stress,
  			cavitation, and
  			kogation in
  			thermal ink jet
  			implementations
  Linear,	The actuator moves	Efficient	High fabrication	USSN 09/112,751;
  normal to	in a direction normal	coupling to ink	complexity may	09/112,787; 09/112,803;
  chip	to the print head	drops ejected	be required to	09/113,084; 09/113,077;
  surface	surface. The nozzle	normal to the	achieve	09/112,816
  	is typically in the	surface	perpendicular
  	line of movement.		motion
  Parallel to	The actuator moves	Suitable for	Fabrication	USSN 09/113,061;
  chip	parallel to the print	planar	complexity	09/112,818; 09/112,772;
  surface	head surface. Drop	fabrication	Friction	09/112,754; 09/112,811;
  	ejection may still be		Stiction	09/112,812; 09/112,813
  	normal to the
  	surface.
  Membrane	An actuator with a	The effective	Fabrication	1982 Howkins USP
  push	high force but small	area of the	complexity	4,459,601
  	area is used to push	actuator	Actuator size
  	a stiff membrane	becomes the	Difficulty of
  	that is in contact	membrane area	integration in a
  	with the ink.		VLSI process
  Rotary	The actuator causes	Rotary levers	Device	USSN 09/113,097;
  	the rotation of some	maybe used to	complexity	09/113,066; 09/112,818;
  	element, such a grill	increase travel	May have	09/112,794
  	or impeller	Small chip area	friction at a
  		requirements	pivot point
  Bend	The actuator bends	A very small	Requires the	1970 Kyser et al USP
  	when energized.	change in	actuator to be	3,946,398
  	This may be due to	dimensions can	made from at	1973 Stemme USP
  	differential thermal	be converted to	least two	3,747,120
  	expansion,	a large motion.	distinct layers,	09/112,802; 09/112,778;
  	piezoelectric		or to have a	09/112,779; 09/113,068;
  	expansion,		thermal	09/112,780; 09/113,083;
  	magnetostriction, or		difference	09/113,121; 09/113,128;
  	other form of		across the	09/113,127; 09/112,756;
  	relative dimensional		actuator	09/112,754; 09/112,811;
  	change.			09/112,812
  Swivel	The actuator swivels	Allows	Inefficient	USSN 09/113,099
  	around a central	operation where	coupling to the
  	pivot. This motion is	the net linear	ink motion
  	suitable where there	force on the
  	are opposite forces	paddle is zero
  	applied to opposite	Small chip area
  	sides of the paddle,	requirements
  	e.g. Lorenz force.
  Straighten	The actuator is	Can be used	Requires careful	USSN 09/113,122;
  	normally bent, and	with shape	balance of	09/112,755
  	straightens when	memory alloys	stresses to
  	energized.	where the	ensure that the
  		austenic phase	quiescent bend
  		is planar	is accurate
  Double	The actuator bends	One actuator	Difficult to	USSN 09/112,813;
  bend	in one direction	can be used to	make the drops	09/112,814; 09/112,764
  	when one element is	power two	ejected by both
  	energized, and	nozzles.	bend directions
  	bends the other way	Reduced chip	identical.
  	when another	size.	A small
  	element is	Not sensitive to	efficiency loss
  	energized.	ambient	compared to
  		temperature	equivalent
  			single bend
  			actuators.
  Shear	Energizing the	Can increase the	Not readily	1985 Fishbeck USP
  	actuator causes a	effective travel	applicable to	4,584,590
  	shear motion in the	of piezoelectric	other actuator
  	actuator material.	actuators	mechanisms
  Radial	The actuator	Relatively easy	High force	1970 Zoltan USP
  con-	squeezes an ink	to fabricate	required	3,683,212
  striction	reservoir, forcing	single nozzles	Inefficient
  	ink from a	from glass	Difficult to
  	constricted nozzle.	tubing as	integrate with
  		macroscopic	VLSI processes
  		structures
  Coil/	A coiled actuator	Easy to	Difficult to	USSN 09/112,815;
  uncoil	uncoils or coils	fabricate as a	fabricate for	09/112,808; 09/112,811;
  	more tightly. The	planar VLSI	non-planar	09/112,812
  	motion of the free	process	devices
  	end of the actuator	Small area	Poor out-of-
  	ejects the ink.	required,	plane stiffness
  		therefore low
  		cost
  Bow	The actuator bows	Can increase the	Maximum	USSN 09/112,819;
  	(or buckles) in the	speed of travel	travel is	09/113,096; 09/112,793
  	middle when	Mechanically	constrained
  	energized.	rigid	High force
  			required
  Push-Pull	Two actuators	The structure is	Not readily	USSN 09/113,096
  	control a shutter.	pinned at both	suitable for ink
  	One actuator pulls	ends, so has a	jets which
  	the shutter, and the	high out-of-	directly push
  	other pushes it.	plane rigidity	the ink
  Curl	A set of actuators	Good fluid flow	Design	USSN 09/113,095;
  inwards	curl inwards to	to the region	complexity	09/112,807
  	reduce the volume	behind the
  	of ink that they	actuator
  	enclose.	increases
  		efficiency
  Curl	A set of actuators	Relatively	Relatively large	USSN 09/112,806
  outwards	curl outwards,	simple	chip area
  	pressurizing ink in a	construction
  	chamber
  	surrounding the
  	actuators, and
  	expelling ink from a
  	nozzle in the
  	chamber.
  Iris	Multiple vanes	High efficiency	High fabrication	USSN 09/112,809
  	enclose a volume of	Small chip area	complexity
  	ink. These		Not suitable for
  	simultaneously		pigmented inks
  	rotate, reducing the
  	volume between the
  	vanes.
  Acoustic	The actuator	The actuator	Large area	1993 Hadimioglu et al,
  vibration	vibrates at a high	can be	required for	EUP 550,192
  	frequency.	physically	efficient	1993 Elrod et al, EUP
  		distant from the	operation at	572,220
  		ink	useful
  			frequencies
  			Acoustic
  			coupling and
  			crosstalk
  			Complex drive
  			circuitry
  			Poor control of
  			drop volume
  			and position
  None	In various ink jet	No moving	Various other	Silverbrook, EP 0771 658
  	designs the actuator	parts	tradeoffs are	A2 and related patent
  	does not move.		required to	applications
  			eliminate	Tone-jet
  			moving parts

• [0063]

  NOZZLE REFILL METHOD

  	Description	Advantages	Disadvantages	Examples

  Surface	This is the normal	Fabrication	Low speed	Thermal ink jet
  tension	way that ink jets are	simplicity	Surface tension	Piezoelectric ink jet
  	refilled. After the	Operational	force relatively	USSN-09/112,751;
  	actuator is energized,	simplicity	small	09/113,084; 09/112,779;
  	it typically returns		compared to	09/112,816; 09/112,819;
  	rapidly to its normal		actuator force	09/113,095; 09/112,809;
  	position. This rapid		Long refill	09/112,780; 09/113,083;
  	return sucks in air		time usually	09/113,121; 09/113,122;
  	through the nozzle		dominates the	09/112,793; 09/112,794;
  	opening. The ink		total repetition	09/113,128; 09/113,127;
  	surface tension at the		rate	09/112,756; 09/112,755;
  	nozzle then exerts a			09/112,754; 09/112,811;
  	small force restoring			09/112,812; 09/112,813;
  	the meniscus to a			09/112,814; 09/112,764;
  	minimum area. This			09/112,765; 09/112,767;
  	force refills the			09/112,768; 09/112,807;
  	nozzle.			09/112,806; 09/112,820;
  				09/112,821
  Shuttered	Ink to the nozzle	High speed	Requires	USSN 09/113,066;
  oscillating	chamber is provided	Low actuator	common ink	09/112,818; 09/112,772;
  ink	at a pressure that	energy, as the	pressure	09/112,815; 09/113,096;
  pressure	oscillates at twice the	actuator need	oscillator	09/113,068; 09/112,808
  	drop ejection	only open or	May not be
  	frequency. When a	close the	suitable for
  	drop is to be ejected,	shutter, instead	pigmented inks
  	the shutter is opened	of ejecting the
  	for 3 half cycles:	ink drop
  	drop ejection,
  	actuator return, and
  	refill. The shutter is
  	then closed to prevent
  	the nozzle chamber
  	emptying during the
  	next negative
  	pressure cycle.
  Refill	After the main	High speed, as	Requires two	USSN 09/112,778
  actuator	actuator has ejected a	the nozzle is	independent
  	drop a second (refill)	actively	actuators per
  	actuator is energized.	refilled	nozzle
  	The refill actuator
  	pushes ink into the
  	nozzle chamber. The
  	refill actuator returns
  	slowly, to prevent its
  	return from emptying
  	the chamber again.
  Positive	The ink is held a	High refill rate,	Surface spill	Silverbrook, EP 0771 658
  ink	slight positive	therefore a	must be	A2 and related patent
  pressure	pressure. After the	high drop	prevented	applications
  	ink drop is ejected,	repetition rate	Highly	Alternative for: USSN
  	the nozzle chamber	is possible	hydrophobic	09/112,751; 09/112,787;
  	fills quickly as		print head	09/112,802; 09/112,803;
  	surface tension and		surfaces are	09/113,097; 09/113,099;
  	ink pressure both		required	09/113,084; 09/112,779;
  	operate to refill the			09/113,077; 09/113,061;
  	nozzle.			09/112,818; 09/112,816;
  				09/112,819; 09/113,095;
  				09/112,809; 09/112,780;
  				09/113,083; 09/113,121;
  				09/113,122; 09/112,793;
  				09/112,794; 09/113,128,
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821

• [0064]

  METHOD OF RESTRICTING BACK-FLOW THROUGH INLET

  	Description	Advantages	Disadvantages	Examples

  Long inlet	The ink inlet	Design	Restricts refill	Thermal ink jet
  channel	channel to the	simplicity	rate	Piezoelectric ink jet
  	nozzle chamber is	Operational	May result in a	USSN 09/112,807;
  	made long and	simplicity	relatively large	09/112,806
  	relatively narrow,	Reduces	chip area
  	relying on viscous	crosstalk	Only partially
  	drag to reduce inlet		effective
  	back-flow.
  Positive	The ink is under a	Drop selection	Requires a	Silverbrook, EP 0771 658
  ink	positive pressure, so	and separation	method (such	A2 and related patent
  pressure	that in the quiescent	forces can be	as a nozzle rim	applications
  	state some of the ink	reduced	or effective	Possible operation of the
  	drop already	Fast refill time	hydrophobizing,	following:
  	protrudes from the		or both) to	USSN 09/112,751;
  	nozzle.		prevent	09/112,787; 09/112,802;
  	This reduces the		flooding of the	09/112,803; 09/113,097;
  	pressure in the		ejection	09/113,099; 09/113,084;
  	nozzle chamber		surface of the	09/112,778; 09/112,779;
  	which is required to		print head.	09/113,077; 09/113,061;
  	eject a certain			09/112,816; 09/112,819;
  	volume of ink. The			09/113,095; 09/112,809;
  	reduction in			09/112,780; 09/113,083;
  	chamber pressure			09/113,121; 09/113,122;
  	results in a reduction			09/112,793; 09/112,794;
  	in ink pushed out			09/113,128; 09/113,127;
  	through the inlet.			09/112,756; 09/112,755;
  				09/112,754; 09/112,811;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  Baffle	One or more baffles	The refill rate is	Design	HP Thermal Ink Jet
  	are placed in the	not as restricted	complexity	Tektronix piezoelectric ink
  	inlet ink flow. When	as the long inlet	May increase	jet
  	the actuator is	method.	fabrication
  	energized, the rapid	Reduces	complexity
  	ink movement	crosstalk	(e.g. Tektronix
  	creates eddies which		hot melt
  	restrict the flow		Piezoelectric
  	through the inlet.		print heads).
  	The slower refill
  	process is
  	unrestricted, and
  	does not result in
  	eddies.
  Flexible	In this method	Significantly	Not applicable	Canon
  flap	recently disclosed	reduces back-	to most ink jet
  restricts	by Canon, the	flow for edge-	configurations
  inlet	expanding actuator	shooter thermal	Increased
  	(bubble) pushes on a	ink jet devices	fabrication
  	flexible flap that		complexity
  	restricts the inlet.		Inelastic
  			deformation of
  			polymer flap
  			results in creep
  			over extended
  			use
  Inlet filter	A filter is located	Additional	Restricts refill	USSN 09/112,803;
  	between the ink inlet	advantage of	rate	09/113,061; 09/113,083;
  	and the nozzle	ink filtration	May result in	09/112,793; 09/113,128;
  	chamber. The filter	Ink filter may	complex	09/113,127
  	has a multitude of	be fabricated	construction
  	small holes or slots,	with no
  	restricting ink flow.	additional
  	The filter also	process steps
  	removes particles
  	which may block the
  	nozzle.
  Small inlet	The ink inlet	Design	Restricts refill	USSN 09/112,787;
  compared	channel to the	simplicity	rate	09/112,814; 09/112,820
  to nozzle	nozzle chamber has		May result in a
  	a substantially		relatively large
  	smaller cross section		chip area
  	than that of the		Only partially
  	nozzle, resulting in		effective
  	easier ink egress out
  	of the nozzle than
  	out of the inlet.
  Inlet	A secondary	Increases speed	Requires	USSN 09/112,778
  shutter	actuator controls the	of the ink-jet	separate refill
  	position of a shutter,	print head	actuator and
  	closing off the ink	operation	drive circuit
  	inlet when the main
  	actuator is
  	energized.
  The inlet is	The method avoids	Back-flow	Requires	USSN 09/112,751;
  located	the problem of inlet	problem is	careful design	09/112,802; 09/113,097;
  behind the	back-flow by	eliminated	to minimize	09/113,099; 09/113,084;
  ink-	arranging the ink-		the negative	09/112,779; 09/113,077;
  pushing	pushing surface of		pressure	09/112,816; 09/112,819;
  surface	the actuator between		behind the	09/112,809; 09/112,780;
  	the inlet and the		paddle	09/113,121; 09/112,794;
  	nozzle.			09/112,756; 09/112,755;
  				09/112,754; 09/112,811;
  				09/112,812; 09/112,813;
  				09/112,765; 09/112,767;
  				09/112,768
  Part of the	The actuator and a	Significant	Small increase	USSN 09/113,084;
  actuator	wall of the ink	reductions in	in fabrication	09/113,095; 09/113,122;
  moves to	chamber are	back-flow can	complexity	09/112,764
  shut off	arranged so that the	be achieved
  the inlet	motion of the	Compact
  	actuator closes off	designs possible
  	the inlet.
  Nozzle	In some	Ink back-flow	None related to	Silverbrook, EP 0771 658
  actuator	configurations of	problem is	ink back-flow	A2 and related patent
  does not	ink jet, there is no	eliminated	on actuation	applications
  result in	expansion or			Valve-jet
  ink back-	movement of an			Tone-jet
  flow	actuator which may
  	cause ink back-flow
  	through the inlet.

• [0065]

  NOZZLE CLEARING METHOD

  	Description	Advantages	Disadvantages	Examples

  Normal	All of the nozzles	No added	May not be	Most ink jet systems
  nozzle	are fired	complexity on	sufficient to	USSN 09/112,751;
  firing	periodically, before	the print head	displace dried	09/112,787; 09/112,802;
  	the ink has a chance		ink	09/112,803; 09/113,097;
  	to dry. When not in			09/113,099; 09/113,084;
  	use the nozzles are			09/112,778; 09/112,779;
  	sealed (capped)			09/113,077; 09/113,061;
  	against air.			09/112,816; 09/112,819;
  	The nozzle firing is			09/113,095; 09/112,809;
  	usually performed			09/112,780; 09/113,083;
  	during a special			09/113,121; 09/113,122;
  	clearing cycle, after			09/112,793; 09/112,794;
  	first moving the			09/113,128; 09/113,127;
  	print head to a			09/112,756; 09/112,755;
  	cleaning station.			09/112,754; 09/112,811;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821
  Extra	In systems which	Can be highly	Requires	Silverbrook, EP 0771 658
  power to	heat the ink, but do	effective if the	higher drive	A2 and related patent
  ink heater	not boil it under	heater is	voltage for	applications
  	normal situations,	adjacent to the	clearing
  	nozzle clearing can	nozzle	May require
  	be achieved by over-		larger drive
  	powering the heater		transistors
  	and boiling ink at
  	the nozzle.
  Rapid	The actuator is fired	Does not	Effectiveness	May be used with: USSN
  success-	in rapid succession.	require extra	depends	09/112,751; 09/112,787;
  ion of	In some	drive circuits on	substantially	09/112,802; 09/112,803;
  actuator	configurations, this	the print head	upon the	09/113,097; 09/113,099;
  pulses	may cause heat	Can be readily	configuration	09/113,084; 09/112,778;
  	build-up at the	controlled and	of the ink jet	09/112,779; 09/113,077;
  	nozzle which boils	initiated by	nozzle	09/112,816; 09/112,819;
  	the ink, clearing the	digital logic		09/113,095; 09/112,809;
  	nozzle. In other			09/112,780; 09/113,083;
  	situations, it may			09/113,121; 09/112,793;
  	cause sufficient			09/112,794; 09/113,128;
  	vibrations to			09/113,127; 09/112,756;
  	dislodge clogged			09/112,755; 09/112,754;
  	nozzles.			09/112,811; 09/112,813;
  				09/112,814; 09/112,764;
  				09/112,765; 09/112,767;
  				09/112,768; 09/112,807;
  				09/112,806; 09/112,820;
  				09/112,821
  Extra	Where an actuator is	A simple	Not suitable	May be used with: USSN
  power to	not normally driven	solution where	where there is	09/112,802; 09/112,778;
  ink	to the limit of its	applicable	a hard limit to	09/112,819; 09/113,095;
  pushing	motion, nozzle		actuator	09/112,780; 09/113,083;
  actuator	clearing may be		movement	09/113,121; 09/112,793;
  	assisted by			09/113,128; 09/113,127;
  	providing an			09/112,756; 09/112,755;
  	enhanced drive			09/112,765; 09/112,767;
  	signal to the			09/112,768; 09/112,807;
  	actuator.			09/112,806; 09/112,820;
  				09/112,821
  Acoustic	An ultrasonic wave	A high nozzle	High	USSN 09/113,066;
  resonance	is applied to the ink	clearing	implementation	09/112,818; 09/112,772;
  	chamber. This wave	capability can	cost if	09/112,815; 09/113,096;
  	is of an appropriate	be achieved	system does	09/113,068; 09/112,808
  	amplitude and	May be	not already
  	frequency to cause	implemented at	include an
  	sufficient force at	very low cost in	acoustic
  	the nozzle to clear	systems which	actuator
  	blockages. This is	already include
  	easiest to achieve if	acoustic
  	the ultrasonic wave	actuators
  	is at a resonant
  	frequency of the ink
  	cavity.
  Nozzle	A microfabricated	Can clear	Accurate	Silverbrook, EP 0771 658
  clearing	plate is pushed	severely	mechanical	A2 and related patent
  plate	against the nozzles.	clogged nozzles	alignment is	applications
  	The plate has a post		required
  	for every nozzle. A		Moving parts
  	post moves through		are required
  	each nozzle,		There is risk of
  	displacing dried ink.		damage to the
  			nozzles
  			Accurate
  			fabrication is
  			required
  Ink	The pressure of the	May be	Requires	May be used with ink jets
  pressure	ink is temporarily	effective where	pressure pump	covered by USSN
  pulse	increased so that ink	other methods	or other	09/112,751; 09/112,787;
  	streams from all of	cannot be used	pressure	09/112,802; 09/112,803;
  	the nozzles. This		actuator	09/113,097; 09/113,099;
  	may be used in		Expensive	09/113,084; 09/113,066;
  	conjunction with		Wasteful of	09/112,778; 09/112,779;
  	actuator energizing.		ink	09/113,077; 09/113,061;
  				09/112,818; 09/112,816;
  				09/112,772; 09/112,819;
  				09/112,815; 09/113,096;
  				09/113,068; 09/113,095;
  				09/112,808; 09/112,809;
  				09/112,780; 09/113,083;
  				09/113,121; 09/113,122;
  				09/112,793; 09/112,794;
  				09/113,128; 09/113,127;
  				09/112,756; 09/112,755;
  				09/112,754; 09/112,811;
  				09/112,812; 09/112,813;
  				09/112,814; 09/112,764;
  				09/112,765; 09/112,767;
  				09/112,768; 09/112,807;
  				09/112,806; 09/112,820;
  				09/112,821
  Print head	A flexible ‘blade’ is	Effective for	Difficult to use	Many ink jet systems
  wiper	wiped across the	planar print	if print head
  	print head surface.	head surfaces	surface is non-
  	The blade is usually	Low cost	planar or very
  	fabricated from a		fragile
  	flexible polymer,		Requires
  	e.g. rubber or		mechanical
  	synthetic elastomer.		parts
  			Blade can wear
  			out in high
  			volume print
  			systems
  Separate	A separate heater is	Can be effective	Fabrication	Can be used with many ink
  ink boiling	provided at the	where other	complexity	jets covered by USSN
  heater	nozzle although the	nozzle clearing		09/112,751; 09/112,787;
  	normal drop e-	methods cannot		09/112,802; 09/112,803;
  	ection mechanism	be used		09/113,097; 09/113,099;
  	does not require it.	Can be		09/113,084; 09/113,066;
  	The heaters do not	implemented at		09/112,778; 09/112,779;
  	require individual	no additional		09/113,077; 09/113,061;
  	drive circuits, as	cost in some ink		09/112,818; 09/112,816;
  	many nozzles can be	jet		09/112,772; 09/112,819;
  	cleared	configurations		09/112,815; 09/113,096;
  	simultaneously, and			09/113,068; 09/113,095;
  	no imaging is			09/112,808; 09/112,809;
  	required.			09/112,780; 09/113,083;
  				09/113,121; 09/113,122;
  				09/112,793; 09/112,794;
  				09/113,128; 09/113,127;
  				09/112,756; 09/112,755;
  				09/112,754; 09/112,811;
  				09/112,812; 09/112,813;
  				09/112,814; 09/112,764;
  				09/112,765; 09/112,767;
  				09/112,768; 09/112,807;
  				09/112,806; 09/112,820;
  				09/112,821

• [0066]

  NOZZLE PLATE CONSTRUCTION

  	Description	Advantages	Disadvantages	Examples

  Electro-	A nozzle plate is	Fabrication	High	Hewlett Packard Thermal
  formed	separately fabricated	simplicity	temperatures	Ink jet
  nickel	from electroformed		and pressures
  	nickel, and bonded		are required to
  	to the print head		bond nozzle
  	chip.		plate
  			Minimum
  			thickness
  			constraints
  			Differential
  			thermal
  			expansion
  Laser	Individual nozzle	No masks	Each hole must	Canon Bubblejet
  ablated or	holes are ablated by	required	be individually	1988 Sercel et al., SPIE,
  drilled	an intense UV laser	Can be quite	formed	Vol. 998 Excimer Beam
  polymer	in a nozzle plate,	fast	Special	Applications, pp. 76-83
  	which is typically a	Some control	equipment	1993 Watanabe et al.,
  	polymer such as	over nozzle	required	USP 5,208,604
  	polyimide or	profile is	Slow where
  	polysulphone	possible	there are many
  		Equipment	thousands of
  		required is	nozzles per
  		relatively low	print head
  		cost	May produce
  			thin burrs at
  			exit holes
  Silicon	A separate nozzle	High accuracy	Two part	K. Bean, IEEE
  micro-	plate is	is attainable	construction	Transactions on Electron
  machined	micromachined		High cost	Devices, Vol. ED-25, No.
  	from single crystal		Requires	10, 1978, pp 1185-1195
  	silicon, and bonded		precision	Xerox 1990 Hawkins et al.,
  	to the print head		alignment	USP 4,899,181
  	wafer.		Nozzles may
  			be clogged by
  			adhesive
  Glass	Fine glass	No expensive	Very small	1970 Zoltan USP
  capillaries	capillaries are drawn	equipment	nozzle sizes	3,683,212
  	from glass tubing.	required	are difficult to
  	This method has	Simple to make	form
  	been used for	single nozzles	Not suited for
  	making individual		mass
  	nozzles, but is		production
  	difficult to use for
  	bulk manufacturing
  	of print heads with
  	thousands of
  	nozzles.
  Monolithic,	The nozzle plate is	High accuracy	Requires	Silverbrook, EP 0771 658
  surface	deposited as a layer	(<1 μm)	sacrificial layer	A2 and related patent
  micro-	using standard VLSI	Monolithic	under the	applications
  machined	deposition	Low cost	nozzle plate to	USSN 09/112,751;
  using VLSI	techniques. Nozzles	Existing	form the	09/112,787; 09/112,803;
  litho-	are etched in the	processes can	nozzle	09/113,077; 09/113,061;
  graphic	nozzle plate using	be used	chamber	09/112,815; 09/113,096;
  processes	VLSI lithography		Surface may	09/113,095; 09/112,809;
  	and etching.		be fragile to	09/113,083; 09/112,793;
  			the touch	09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,813;
  				09/112,814; 09/112,764;
  				09/112,765; 09/112,767;
  				09/112,768; 09/112,807;
  				09/112,806; 09/112,820
  Monolithic,	The nozzle plate is a	High accuracy	Requires long	USSN 09/112,802;
  etched	buried etch stop in	(<1 μm)	etch times	09/113,097; 09/113,099;
  through	the wafer. Nozzle	Monolithic	Requires a	09/113,084; 09/113,066;
  substrate	chambers are etched	Low cost	support wafer	09/112,778; 09/112,779;
  	in the front of the	No differential		09/112,818; 09/112,816;
  	wafer, and the wafer	expansion		09/112,772; 09/112,819;
  	is thinned from the			09/113,068; 09/112,808;
  	back side. Nozzles			09/112,780; 09/113,121;
  	are then etched in			09/113,122
  	the etch stop layer.
  No nozzle	Various methods	No nozzles to	Difficult to	Ricoh 1995 Sekiya et al
  plate	have been tried to	become clogged	control drop	USP 5,412,413
  	eliminate the		position	1993 Hadimioglu et al EUP
  	nozzles entirely, to		accurately	550,192
  	prevent nozzle		Crosstalk	1993 Elrod et al EUP
  	clogging. These		problems	572,220
  	include thermal
  	bubble mechanisms
  	and acoustic lens
  	mechanisms
  Trough	Each drop ejector	Reduced	Drop firing	USSN 09/112,812
  	has a trough through	manufacturing	direction is
  	which a paddle	complexity	sensitive to
  	moves. There is no	Monolithic	wicking.
  	nozzle plate.
  Nozzle slit	The elimination of	No nozzles to	Difficult to	1989 Saito et al
  instead of	nozzle holes and	become clogged	control drop	USP 4,799,068
  individual	replacement by a slit		position
  nozzles	encompassing many		accurately
  	actuator positions		Crosstalk
  	reduces nozzle		problems
  	clogging, but
  	increases crosstalk
  	due to ink surface
  	waves

• [0067]

  DROP EJECTION DIRECTION

  	Description	Advantages	Disadvantages	Examples

  Edge	Ink flow is along the	Simple	Nozzles	Canon Bubblejet 1979
  (‘edge	surface of the chip,	construction	limited to edge	Endo et al GB patent
  shooter’)	and ink drops are	No silicon	High	2,007,162
  	ejected from the	etching required	resolution is	Xerox heater-in-pit 1990
  	chip edge.	Good heat	difficult	Hawkins et al USP
  		sinking via	Fast color	4,899,181
  		substrate	printing	Tone-jet
  		Mechanically	requires one
  		strong	print head per
  		Ease of chip	color
  		handing
  Surface	Ink flow is along the	No bulk silicon	Maximum ink	Hewlett-Packard TIJ 1982
  (‘roof	surface of the chip,	etching required	flow is	Vaught et al USP
  shooter’)	and ink drops are	Silicon can	severely	4,490,728
  	ejected from the	make an	restricted	USSN 09/112,787,
  	chip surface, normal	effective heat		09/113,077; 09/113,061;
  	to the plane of the	sink		09/113,095; 09/112,809
  	chip.	Mechanical
  		strength
  Through	Ink flow is through	High ink flow	Requires bulk	Silverbrook, EP 0771 658
  chip,	the chip, and ink	Suitable for	silicon etching	A2 and related patent
  forward	drops are ejected	pagewidth print		applications
  (‘up	from the front	heads		USSN 09/112,803;
  shooter’)	surface of the chip.	High nozzle		09/112,815; 09/113,096;
  		packing density		09/113,083; 09/112,793;
  		therefore low		09/112,794; 09/113,128;
  		manufacturing		09/113,127; 09/112,756;
  		cost		09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821
  Through	Ink flow is through	High ink flow	Requires wafer	USSN 09/112,751;
  chip,	the chip, and ink	Suitable for	thinning	09/112,802; 09/113,097;
  reverse	drops are ejected	pagewidth print	Requires	09/113,099; 09/113,084;
  (‘down	from the rear surface	heads	special	09/113,066; 09/112,778;
  shooter’)	of the chip.	High nozzle	handling	09/112,779; 09/112,818;
  		packing density	during	09/112,816; 09/112,772;
  		therefore low	manufacture	09/112,819;
  		manufacturing		09/113,068; 09/112,808;
  		cost		09/112,780; 09/113,121;
  				09/113,122
  Through	Ink flow is through	Suitable for	Pagewidth	Epson Stylus
  actuator	the actuator, which	piezoelectric	print heads	Tektronix hot melt
  	is not fabricated as	print heads	require several	piezoelectric ink jets
  	part of the same		thousand
  	substrate as the		connections to
  	drive transistors.		drive circuits
  			Cannot be
  			manufactured
  			in standard
  			CMOS fabs
  			Complex
  			assembly
  			required

• [0068]

  INK TYPE

  	Description	Advantages	Disadvantages	Examples

  Aqueous,	Water based ink	Environmental-	Slow drying	Most existing ink jets
  dye	which typically	ly friendly	Corrosive	USSN 09/112,751;
  	contains: water, dye,	No odor	Bleeds on	09/112,787; 09/112,802;
  	surfactant,		paper	09/112,803; 09/113,097;
  	humectant, and		May	09/113,099; 09/113,084;
  	biocide.		strikethrough	09/113,066; 09/112,778;
  	Modern ink dyes		Cockles paper	09/112,779; 09/113,077;
  	have high water-			09/113,061; 09/112,818;
  	fastness, light			09/112,816; 09/112,772;
  	fastness			09/112,819; 09/112,815;
  				09/113,096; 09/113,068;
  				09/113,095; 09/112,808;
  				09/112,809; 09/112,780;
  				09/113,083; 09/113,121;
  				09/113,122; 09/112,793;
  				09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821
  				Silverbrook, EP 0771 658
  				A2 and related patent
  				applications
  Aqueous,	Water based ink	Environmental-	Slow drying	USSN 09/112,787;
  pigment	which typically	ly friendly	Corrosive	09/112,803; 09/112,808;
  	contains: water,	No odor	Pigment may	09/113,122; 09/112,793;
  	pigment, surfactant,	Reduced bleed	clog nozzles	09/113,127
  	humectant, and	Reduced	Pigment may	Silverbrook, EP 0771 658
  	biocide.	wicking	clog actuator	A2 and related patent
  	Pigments have an	Reduced	mechanisms	applications
  	advantage in reduced	strikethrough	Cockles paper	Piezoelectric ink-jets
  	bleed, wicking and			Thermal ink jets (with
  	strikethrough.			significant restrictions)
  Methyl	MEK is a highly	Very fast	Odorous	USSN 09/112,751;
  Ethyl	volatile solvent used	drying	Flammable	09/112,787; 09/112,802;
  Ketone	for industrial printing	Prints on		09/112,803; 09/113,097;
  (MEK)	on difficult surfaces	various		09/113,099; 09/113,084;
  	such as aluminum	substrates such		09/113,066; 09/112,778;
  	cans.	as metals and		09/112,779; 09/113,077;
  		plastics		09/113,061; 09/112,818;
  				09/112,816; 09/112,772;
  				09/112,819; 09/112,815;
  				09/113,096; 09/113,068;
  				09/113,095; 09/112,808;
  				09/112,809; 09/112,780;
  				09/113,083; 09/113,121;
  				09/113,122; 09/112,793;
  				09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821
  Alcohol	Alcohol based inks	Fast drying	Slight odor	USSN 09/112,751;
  (ethanol,	can be used where	Operates at	Flammable	09/112,787; 09/112,802;
  2-butanol,	the printer must	sub-freezing		09/112,803; 09/113,097;
  and	operate at	temperatures		09/113,099; 09/113,084;
  others)	temperatures below	Reduced paper		09/113,066; 09/112,778;
  	the freezing point of	cockle		09/112,779; 09/113,077;
  	water. An example of	Low cost		09/113,061; 09/112,818;
  	this is in-camera			09/112,816; 09/112,772;
  	consumer			09/112,819; 09/112,815;
  	photographic			09/113,096; 09/113,068;
  	printing.			09/113,095; 09/112,808;
  				09/112,809; 09/112,780;
  				09/113,083; 09/113,121;
  				09/113,122; 09/112,793;
  				09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821
  Phase	The ink is solid at	No drying	High viscosity	Tektronix hot melt
  change	room temperature,	time-ink	Printed ink	piezoelectric ink jets
  (hot melt)	and is melted in the	instantly	typically has a	1989 Nowak USP
  	print head before	freezes on the	‘waxy’ feel	4,820,346
  	jetting. Hot melt inks	print medium	Printed pages	USSN 09/112,751;
  	are usually wax	Almost any	may ‘block’	09/112,787; 09/112,802;
  	based, with a melting	print medium	Ink	09/112,803; 09/113,097;
  	point around 80° C.	can be used	temperature	09/113,099; 09/113,084;
  	After jetting the ink	No paper	may be above	09/113,066; 09/112,778;
  	freezes almost	cockle occurs	the curie point	09/112,779; 09/113,077;
  	instantly upon	No wicking	of permanent	09/113,061; 09/112,818;
  	contacting the print	occurs	magnets	09/112,816; 09/112,772;
  	medium or a transfer	No bleed	Ink heaters	09/112,819; 09/112,815;
  	roller.	occurs	consume	09/113,096; 09/113,068;
  		No	power	09/113,095; 09/112,808;
  		strikethrough	Long warm-up	09/112,809; 09/112,780;
  		occurs	time	09/113,083; 09/113,121;
  				09/113,122; 09/112,793;
  				09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821
  Oil	Oil based inks are	High solubility	High viscosity:	USSN 09/112,751;
  	extensively used in	medium for	this is a	09/112,787; 09/112,802;
  	offset printing. They	some dyes	significant	09/112,803; 09/113,097;
  	have advantages in	Does not	limitation for	09/113,099; 09/113,084;
  	improved	cockle paper	use in ink jets,	09/113,066; 09/112,778;
  	characteristics on	Does not wick	which usually	09/112,779; 09/113,077;
  	paper (especially no	through paper	require a low	09/113,061; 09/112,818;
  	wicking or cockle).		viscosity.	09/112,816; 09/112,772;
  	Oil soluble dies and		Some short	09/112,819; 09/112,815;
  	pigments are		chain and	09/113,096; 09/113,068;
  	required.		multi-branched	09/113,095; 09/112,808;
  			oils have a	09/112,809; 09/112,780;
  			sufficiently	09/113,083; 09/113,121;
  			low viscosity.	09/113,122; 09/112,793;
  			Slow drying	09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821
  Micro-	A microemulsion is a	Stops ink bleed	Viscosity	USSN 09/112,751;
  emulsion	stable, self forming	High dye	higher than	09/112,787; 09/112,802;
  	emulsion of oil,	solubility	water	09/112,803; 09/113,097;
  	water, and surfactant.	Water, oil, and	Cost is slightly	09/113,099; 09/113,084;
  	The characteristic	amphiphilic	higher than	09/113,066; 09/112,778;
  	drop size is less than	soluble dies	water based	09/112,779; 09/113,077;
  	100 nm, and is	can be used	ink	09/113,061; 09/112,818;
  	determined by the	Can stabilize	High surfactant	09/112,816; 09/112,772;
  	preferred curvature of	pigment	concentration	09/112,819; 09/112,815;
  	the surfactant.	suspensions	required	09/113,096; 09/113,068;
  			(around 5%)	09/113,095; 09/112,808;
  				09/112,809; 09/112,780;
  				09/113,083; 09/113,121;
  				09/113,122; 09/112,793;
  				09/112,794; 09/113,128;
  				09/113,127; 09/112,756;
  				09/112,755; 09/112,754;
  				09/112,811; 09/112,812;
  				09/112,813; 09/112,814;
  				09/112,764; 09/112,765;
  				09/112,767; 09/112,768;
  				09/112,807; 09/112,806;
  				09/112,820; 09/112,821

Claims (6)

We claim:

1. A garment creation system comprising:

a pattern generating means for generating at least one garment piece outline and a decorative finish to be imparted to said garment piece; and

a garment fabric printer in communication with said pattern generating means for printing simultaneously said garment piece outline and said decorative finish on to a surface of a bolt of fabric passing through said printer, in use.

2. A garment creation system as claimed inclaim 1 wherein said garment fabric printer prints simultaneously on the surface of the bolt of fabric, a plurality of garment piece outlines, each with their associated decorative finishes.

3. A garment creation system as claimed inclaim 2 wherein said garment fabric printer prints out on the surface of said bolt of fabric instructions for joining said garment pieces together.

4. A garment creation system as claimed inclaim 2 wherein said pattern generating means generates the decorative finishes on each of said pieces so that an image, created by fastening said pieces together to form a garment, appears to be continuous.

5. A garment creation system as claimed inclaim 1 wherein the garment fabric printer is an ink jet printer having an image printing width corresponding to a width of the bolt of fabric.

6. A garment creation system as claimed inclaim 1 wherein the pattern generating means generates garment pieces of different sizes to cater for different sizes and shapes of bodies.

Images