Abstract: An orifice array plate and a charge plate for a continuous ink jet printer print head are integrally fabricated by providing an electrically non-conductive substrate; forming, on one side of the substrate, an orifice plate with an array of orifices; forming, on the other side of the substrate, a charge plate comprising a plurality of charge leads aligned with respective ones of the orifices; and removing at least that portion of the substrate that is between the orifices and the charge leads. The final produce includes an electrically non-conductive substrate; an orifice plate, including an array of orifices, on one side of the substrate; a charge plate, including a plurality of charge leads, on the other side of the substrate such that the charge leads are aligned with respective ones of the orifices; and a plurality of passages through the substrate, said passages extending between the orifices and the charge leads.

Abstract: The turbulence of the air moved through an inkjet print head enclosure is reduced before reaching the printing region between the print head and a print medium by positioning a HEPA filtration system between an air inlet opening in the enclosure and the print head. Turbulence is removed from air moved through the air path by HEPA filtration of the air being drawn into the print head enclosure before reaching the printing region.

Abstract: A drop generator is operated to form large-volume and small-volume droplets by providing a droplet generator having a nozzle and an adjustable stimulation device; supplying liquid to the droplet generator such that a stream of diameter D emanates from the nozzle; activating the stimulation device to produce a first set of perturbations on the liquid stream, the perturbations having a period x such as to cause the liquid stream to form into small-volume droplets; selectively adjusting the stimulation device to produce a second set of perturbations on the liquid stream, the second set of perturbations having a period Nx such as to cause a segment of the liquid stream to form into a large-volume droplet, whereby the large-volume droplet is N times the volume of the small-volume droplets; and further adjusting the stimulation device to produce a third set of perturbations on the liquid stream during the period Nx.

Abstract: A drop generator operable to selectively form a drop having a first size and a drop having a second size from liquid emitted through a nozzle associated with the drop generator. The drop having the first size and the drop having the second size travel along a drop trajectory with the first size being larger than the second size when compared to each other. Each of the drops has a drop velocity. A gas flow deflection system includes a gas flow that is directed at a deflection zone that comprises at least a portion of the drop trajectory. The gas flow in the deflection zone includes a velocity vector having a parallel velocity component and a perpendicular velocity component with the parallel velocity component and the perpendicular velocity component being defined relative to the drop trajectory.

Abstract: The turbulence of the air moved through an inkjet print head enclosure is reduced before reaching the printing region between the print head and a print medium by positioning a HEPA filtration system between an air inlet opening in the enclosure and the print head. Turbulence is removed from air moved through the air path by HEPA filtration of the air being drawn into the print head enclosure before reaching the printing region.

Abstract: The method for shutting down an ink jet printhead and an ink jet printing station, wherein the method includes maintaining a constant positive pressure at the drop generator by closing the cross flush valve or ensuring that the cross flush valve is closed, thereby closing off the fluid return line to create a constant positive pressure through the drop generator and the orifice into the fluid line. The shutdown continues by stopping the flow of fluid from the fluid supply line and circulating cleaning fluid through at least one filter, into the drop generator, out through the orifice structure, into the fluid line, and into a reservoir. The shutdown ends by flowing pressurized air, which is preferably clean of particulates, through the filter, drop generator, orifice structure, and fluid line to displace substantially all the cleaning fluid from the filter, drop generator, and orifice structure.

Abstract: An improved continuous ink jet print station includes a drop generator with a jet array and a drop charging assembly. The drop charging assembly includes a substrate with a first side facing the jet array, and one or more resistive heater elements placed on the substrate aligned with the jet array. The resistive heater elements are discontinuously disposed on portions of the substrate. One or more one charging electrodes are disposed on the first side. The continuous ink jet print station includes a power source for powering the resistive heater elements to heat the substrate to a temperature sufficient to prevent condensation of fluid on the first side.

Abstract: An inkjet printer has a catcher and eyelid seal for sealing against the catcher during startup and shutdown. A wicking means is provided for removing excess ink from a fluid channel of the catcher having an associated catcher plate, in an area of the eyelid seal. The wicking means is positioned in an area at a bottom surface of the fluid channel, without bridging a height of the fluid channel, above the catcher plate, and in close proximity to the eyelid seal, while maintaining a consistent pressure at an entrance to the fluid channel.

Abstract: A system and method are provided for cleaning the printhead of a continuous ink jet printing system. A cleaning fluid is introduced and used to flush ink residues and debris from the interior of the drop generator, the exterior of the orifice plate, the charge plate face and the catcher face. This system and method removes dried ink residues and other debris and deposits by providing a cleaning fluid with a low surface tension to dissolve or flush away the unwanted material from the orifices. This is particularly advantageous in that the flushing and rinsing is accomplished without mechanical contact which could abrade or damage the orifices.

Abstract: An ink jet printing system is provided, having improved reliability. To achieve the improved reliability, the ink jet printer has the capability of changing at least one reliability related parameter in accordance with data associated with an ink. Data associated with the ink relates to the value or setting of at least one parameter in the ink jet printer related to reliability of the ink jet printing system.

Abstract: An alignment apparatus and method is provided for attaching and aligning components of an ink jet printhead of a continuous ink jet printer. First and second bonding surfaces are provided on first and second components, respectively, of the ink jet printhead. The first and second components are then aligned and attached. The attaching can be accomplished by applying an adhesive, which may also incorporate a chemical accelerator, or by distributing an adhesive from a central region of the bonding surfaces to create an adhesive bond between the first and second bonding surfaces.

Abstract: A fixture for installing a flexible wire mesh grip over an elongated cable includes a base having spaced opposite ends and an internal cavity extending longitudinally therebetween. The spaced opposite ends define respective first and second passages opening into the internal cavity. The internal cavity has a cross-sectional size larger than that of a tubular body of the grip in a compressed non-gripping condition to accommodate the presence of the tubular body in the compressed non-gripping condition and of an annular collar secured on one end thereof within the internal cavity. The internal cavity and first and second passages of the base have respective cross-sectional sizes larger than that of the cable to permit insertion of the cable therethrough.

Abstract: The present invention provides for an improvement in the removal of fluid from an ink jet printhead. A branched structure having multiple groups of branches creates a flow geometry, with each group of branches having a connecting trunk. The fluid flow is then able to be directed from each plurality of branches down the connecting trunk. Pressure drops at the branching nodes are minimized by directing the flow from the combined branches down the connected trunk. Expansion losses at the branching nodes are minimized by funneling down the flow at the branching nodes, with the trunk having a narrower channel than the combination of the joined branches.

Abstract: An apparatus and method allows for mounting and aligning of the charge plate/catcher assembly and the droplet generator and has six degrees of freedom of adjustment, including three degrees of freedom of translation and three degrees of freedom of rotation. A first degree of freedom of translation comprises a height adjustment of the resonator relative to the charge plate; a second degree of freedom of translation comprises an alignment adjustment for aligning the plurality of jets with respect to the plurality of charge leads; and a third degree of freedom of translation comprises a reciprocal adjustment for moving the plurality of jets relative to the charge plate.

Abstract: An apparatus and method allow for assembly of a print head apparatus for an ink jet printer. The apparatus comprises control capability for controlling the flow of fluid to the droplet generator and for controlling transfer of data to the droplet charging and collecting element. The control capability for controlling transfer of data to the droplet charging and collecting element is a motherboard containing various elements. The motherboard includes a microcontroller and fiber optics for receiving data and control signals and providing the signals to an input buffer. A RAM provides data memory, and a latch and shift register latch and shift the data from the RAM. A high voltage driver receive data from the latch and shift register. A control state machine communicates with the microcontroller, for handling generation of all control signals for the input buffer, the RAM, and the latch and shift register.

Abstract: An ink jet printer for printing in a wide format includes a plurality of ink jet print heads for producing rows of regularly spaced apart ink jets. The print heads are supported and located by first and second print head carriages that are controllably moveable to locate the print heads to within a fraction of an ink jet spacing in directions both parallel with and perpendicular to the direction of movement of the print medium. The first and second carriages are spaced apart along the direction of relative movement of the print medium by a distance sufficient to permit the first and second print heads to be arranged in an interleaved relation, or an end to end relation.

Abstract: A male electrical connector having an insulating plug body and a cylindrical sleeve surrounding conductive prongs extending from the plug body. The sleeve has at least one aperture in a side wall thereof to removably receive a locking member. The removable locking member is preferably a padlock having a substantially U-shaped shackle extending through the aperture in the sleeve to prevent insertion of the male connector into the mating female connector.

Abstract: An ink concentration sensor maintains ink concentration in an ink jet printing system. The ink concentration sensor includes a transparent fluid chamber and an infrared light source for directing a beam of IR light at the fluid chamber. A first sensor is located for receiving IR light reflected from the surface of the chamber and providing a reference signal and a second sensor is located for receiving IR light transmitted through the chamber to produce a concentration signal. A circuit receives the reference signal and generates a corrected concentration signal.