Abstract: An apparatus and methods for using a Variable Orifice Capillary Wave Printer are disclosed. The invention as described herein provides a capability to transfer high resolution graphical images onto a projection medium (14) with pseudo-gray-scale (i.e. variable spot-size). A standing fluid ripple wave (38) or capillary wave is generated along a narrow channel (20) at the top of an ink reservoir (16), upon the free fluid surface (27). The capillary wave (38) is spatially stablized with an elongated slotted bar (30) of anisotropically etched signal crystal silicon. Piezoelectric pushers (34) are positioned at the anti-nodes (42) of the stabilized standing capillary wave (38) to selectively restrict the narrow slots (32) etched into the slotted silicon bar (30). Selective actuation of one or more piezoelectric pusher (34) for a predetermined length of time results in the ejection of a stream of fluid droplets (12).

Abstract: To improve the tolerance of acoustic ink printers to changes in their free ink surface levels, provision is made for significantly reducing the effect of half wave resonances on the acoustic power density of the acoustic beam or beams that are incident on the free ink surface of such a printer, thereby reducing its focusing sensitivity. Some of the approaches that are taken to accomplish this rely upon acoustic losses to damp out the halfwave resonances and anti-resonances, while others employ multi-frequency rf voltage pulses for driving the droplet ejector or ejectors so that the acoustic power perturbations caused by the half wave resonances and anti-resonances of the different frequencies tend to neutralize each other.

Abstract: This disclosure relates to semiconductor varactors, such as thin film poly-Si varactors, which have larger effective gate areas in accumulation than in depletion, together with capacitive switching ratios which are essentially determined by the ratio of their effective gate area in accumulation to their effective gate area in depletion. To that end, such a varactor has a fully depletable active semiconductor layer, such as a thin poly-Si film, and is constructed so that at least a part of its active layer is sandwiched between a relatively thin dielectric layer and a relatively thick dielectric layer. The thin dielectric layer, in turn, is sandwiched between the active semiconductor layer and a gate electrode. Furthermore, one or more ground electrodes are electrically coupled to laterally offset portions of the active semiconductor layer in partial overlapping alignment with the gate electrode.

Abstract: In accordance with the present invention, an acoustic ink printer comprises a pool of liquid ink having a free surface in intimate contact with the inner face of a perforated membrane. The printer addresses all pixel positions within its image field via substantially uniform, relatively large diameter apertures which extend through the membrane on centers that are aligned with respective ones of the pixel positions. In operation, one or more focused acoustic beams selectively eject individual droplets of ink from the ink menisci that extend across the apertures. Accordingly, the membrane is positioned and the bias pressure that is applied to the ink is selected so that the menisci essentially remain within the focal plane of such beam or beams.

Abstract: An acoustic ink printhead having improved ink drop ejection control includes a substrate having an array of acoustic lenses at its upper surface for bringing rf acoustic waves to a predetermined focus and a layer of acoustically reflective material of a thickness equal to an odd multiple of one quarter of the wavelength of the acoustic rf waves passing through it having openings corresponding to and positioned above each lens. Ink from an ink pool is allowed to couple acoustically to the lenses at each opening for receiving the focussed acoustic rf wave, while the layer acoustically isolates the interstitial regions between each lens by reflecting the acoustic rf waves incident on the upper surface of the substrate in those regions.

Abstract: Amorphous silicon (aSi) voltage-controlled, variable capacitors (varactors) are utilized as rf amplitude modulators, such as for amplitude modulating the rf applied to an acoustic ink printhead. Large area fabrication processes are employed for vertically integrating these varactors with such printheads or other devices.

Abstract: The output surface of an acoustic printhead having one or more concave acoustic beam forming devices for supplying focused acoustic beams to eject droplets of ink on demand from the surface of a pool of ink is planarized by filling those concave devices with a solid material having an acoustic impedance and an acoustic velocity which are intermediate the acoustic impedance and the acoustic velocity, respectively, of the ink and of the printhead. This not only facilitates the cleaning of the printhead, but also eliminates the edges upon which an optional ink transport or the like may tend to drag. The outer surface of the filler may be essentially flush with the face of the printhead, or the filler may overcoat the printhead.

Abstract: A printhead for an acoustic printer comprises one or more acoustic microlenses, each of which brings an acoustic beam to focus approximately at the free surface of a pool of ink for ejecting individual droplets of ink from the pool on demand. As used herein, an "acoustic microlens" is defined as being an acoustic lens having an aperture diameter which is less than an order of magnitude greater than the wavelength of the incident acoustic wave (i.e., the acoustic wave which illuminates the lens).

Abstract: To facilitate the fabrication of acoustic printheads, arrays of spherical acoustic lenses are provided for bringing rf acoustic waves to essentially diffraction limited focii at or near the free surface of a pool of ink. These lenses produce focal patterns which are relatively free of localized amplitude variations, so they may be employed to fabricate acoustic printheads having relatively stable characteristics for acoustic printing.

Abstract: A nozzleless droplet ejector for ejecting droplets from a free surface of a pool of liquid, such as a pool of ink, comprises a selectively energizeable emission controller for generating a freely propagating capillary wave on the surface of the pool to provide on/off timing control and/or ejection trajectory angle control for the ejector. The controller comprises a conductor and a counter electrode. The conductor is immersed in the pool, whereby a capillary surface wave is generated when a voltage is applied across the conductor and the counter electrode. In one embodiment, a focused ultrasonic acoustic wave or the like perturbs the pressure acting on the free surface of the pool, and the capillary wave supplied by the controller coherently interacts with that pressure perturbence to provide the desired control.Separate controllers may be provided for independently controlling the ejectors of multiple ejector arrays.

Abstract: To facilitate the use of hot melt inks in acoustic ink printers of the type having a printhead including one or more acoustic droplet ejectors for supplying focused acoustic beams, such a printer comprises a carrier for transporting a generally uniformly thick film of hot melt ink across its printhead, together with a heating means for liquefying the ink as it nears the printhead. The droplet ejector or ejectors are acoustically coupled to the ink via the carrier, and their output focal plane is essentially coplanar with the free surface of the liquefied ink, thereby enabling them to eject individual droplets of ink therefrom on command. The ink, on the other hand, is moved across the printhead at a sufficiently high rate to maintain the free surface which it presents to the printhead at a substantially constant level.

Abstract: Provision is made spatially stabilizing standing capillary surface waves in fixed and repeatable locations with respect to stationary external references. For spatially stabilizing such a wave on the free surface of a volume of liquid, the wave propagation characteristics of the free surface of liquid are periodically varied in a spatially stable manner at a spatial frequency equal to the spatial frequency of the standing wave or a subharmonic thereof, thereby locking the crests and troughs of the standing wave in predetermined spatial locations. A spatially periodic pattern of notches in a wall or base plate bounding the free surface of the liquid may be employed to physically modulate its wave propagation characteristics at a suitable spatial frequency. Alternatively freely propagating secondary capillary surface waves may be launched from spatially periodic sites along the free surface of the liquid to actively modulate its wave propagation characteristics at the diesired spatial frequency.

Abstract: Provision is made for selectively addressing inividual crests of traveling or standing capillary surface waves to eject droplets from the selected crests on command. To that end, the addressing mechanism of this invention locally increase the surface pressure acting on the selected crests and/or locally reduce the surface tension of the liquid within the selected crests. The preferred addressing mechanisms have sufficient spatial resolution to address a single crest substantially independently of its neighbors.Discrete addressing mechanisms having a plurality of individual addressing elements are especially attractive for liquid ink printing and similar applications, not only because their individual addressing elements may be spatially fixed, but also because the spatial frequency of their addressing elements may be matched to the spatial frequency of the capillary wave. Such frequency matching enables selected crests of the capillary wave to be addressed in parallel, such as for line printing.