System and method for printing ink images in accordance with sustainability goals
Patent Information
- Application Number
- JP2024125639
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Priority Date
- 2023-08-22
- Filing Date
- 2024-08-01
- Publication Date
- 2025-03-07
Smart Images
Figure 2025031584000001_ABST
Abstract
Description
[Technical field]
[0001] FIELD OF THE DISCLOSURE This disclosure relates generally to devices that produce ink images on media, and more particularly to printing ink images in accordance with sustainability goals. [Background technology]
[0002] Inkjet imaging devices, also known as inkjet printers, eject liquid ink from a printhead to form an image on an image receiving surface. The printhead includes a plurality of inkjets arranged in an array. Each inkjet has a thermal or piezoelectric actuator coupled to a printhead controller. The printhead controller generates firing signals corresponding to digital data content that defines the image. The actuators in the printhead respond to the firing signals by expanding into ink chambers fluidly connected to the nozzles to eject ink droplets from the nozzles and onto the image receiving surface to form an ink image that corresponds to the digital image content used to generate the firing signals. The image receiving surface is typically a continuous web of media material or a series of media sheets.
[0003] Inkjet printers used to generate color images typically include multiple printhead modules. Each printhead module typically includes one or more printheads that eject a single color of ink. In a typical inkjet color printer, four printhead modules are positioned in the process direction, with each printhead module ejecting a different color of ink. The four most frequently used ink colors are cyan, magenta, yellow, and black. The common name for such printers is a CMYK color printer. Some CMYK color printers have two printhead modules that print each color of ink. The printhead modules that print the same color of ink are offset from each other in the cross-process direction by half the distance between adjacent inkjets, doubling the number of pixels per inch and increasing the density of the lines of ink color ejected by the printheads in the two modules. As used in this document, the term "process direction" refers to the direction of movement of the image receiving surface as it passes the printheads in the printer, and the term "cross-process direction" refers to the direction perpendicular to the process direction in the plane of the image receiving surface.
[0004] Inkjets, particularly those in printheads that jet water-based inks, need to be fired periodically to help prevent the ink in the nozzles from drying out. As the inkjets jet significant amounts of ink to create high area coverage in the ink image, the nozzles in the printhead can dry out. Operation of a high percentage of inkjets in a portion of a faceplate on the printhead can generate a large number of satellite drops that tend to adhere to the faceplate. Satellite drops are small ink drops that separate from larger drops that travel from the nozzles to the image receiving substrate. The accumulation of these satellite drops on the faceplate can clog the nozzles in the faceplate. Additionally, if the inkjets in the printhead do not operate frequently enough, for example when low ink area coverage image portions are printed, the ink in the inkjets can dry out, rendering the inkjets inoperable. To maintain the inkjets in operation, the printhead modules are moved from a position opposite the path of the image receiving substrate to a printhead maintenance station where the printheads are purged. Purging a printhead means that pressurized gas or liquid is applied to ink supply chambers in the printhead to force ink from the chambers into the nozzles where it is ejected from the nozzles onto the faceplate. One or more wipers are then moved across the faceplate to remove the purged ink from the faceplate to a waste ink container.
[0005] Disposal of waste ink can present environmental problems. Rather than sending the waste ink into bottles where it is eventually shipped and permanently stored as a water-based ink, the ink can be heated to a temperature sufficient to evaporate the water or other solvent from the ink. This evaporation reduces the volume of the waste ink and the solids can be disposed of in a more environmentally friendly manner. However, heating the waste ink requires energy that is not used for the primary function of printing, i.e., ink image production. As a result, the energy costs of operating an inkjet printer can be significantly higher than necessary. Thus, inkjet printers would benefit from being able to process the waste ink in a manner that reduces the cost of operating the inkjet printer without adversely affecting the environment. Summary of the Invention
[0006] The color inkjet printer is configured to treat waste ink in a manner that reduces the cost of operating the inkjet printer without adversely affecting the environment. The color inkjet printer includes a printhead maintenance station configured to perform at least one purge cycle on at least one printhead in the inkjet printer to generate waste ink, a waste ink treatment system fluidly coupled to the printhead maintenance system to receive the waste ink from the printhead maintenance station, the waste ink treatment system configured to separate the waste ink into solid ink pigment particles and a solvent stream, and a humidification chamber fluidly coupled to the waste ink treatment system to receive the solvent stream from the waste ink treatment system, the humidification chamber configured to humidify the solvent stream received from the waste ink treatment system and direct the humidified solvent stream to a print zone of the inkjet printer.
[0007] A method of operating a color inkjet printer processes waste ink in a manner that reduces the cost of operating the inkjet printer without adversely affecting the environment. The method includes performing at least one purge cycle on at least one printhead in the inkjet printer to produce waste ink, separating the waste ink into solid ink pigment particles and a solvent stream, humidifying the solvent stream, and directing the humidified solvent stream to a print zone of the inkjet printer.
[0008] A kit may be retroactively installed in a color inkjet printer such that the printer can be operated to dispose of waste ink in a manner that reduces the cost of operating the inkjet printer without adversely affecting the environment. The kit includes a replacement waste ink container configured to bleed waste ink from a printhead maintenance station, a waste ink treatment system, a humidification chamber, three pneumatic devices, and two air baffles with U-shaped clips for each printhead equal to half the number of printhead modules in the printer. [Brief description of the drawings]
[0009] The foregoing aspects and other features of a color inkjet printer, a method of operating a color inkjet printer, and a kit that may be installed in a printer with an inkjet so that the printer processes waste ink in a manner that reduces the cost of operating the inkjet printer without adversely affecting the environment, are explained in the following description, taken in conjunction with the accompanying drawings. [Figure 1] 1 is a schematic diagram of a color inkjet printer that processes waste ink in a manner that reduces the cost of operating an inkjet printer without adversely affecting the environment. [Diagram 2] 2 illustrates the print zone of the printer shown in FIG. 1 and a printhead maintenance station positioned adjacent the print zone. [Diagram 3]A waste ink treatment system is shown that receives waste ink from a printhead maintenance station and separates the solvent from the solid ink pigment particles such that the solid ink particles are collected in a container configured for removal from the treatment system. [Figure 4] 4 shows a humidification chamber that receives a solvent stream from the waste ink treatment system of FIG. 3 and processes the solvent stream for use in the print zone of the inkjet printer of FIG. 1. [Diagram 5] 2. An air baffle system is shown that may be fluidly coupled to the humidification chamber of FIG. 3 and added to the printhead of the inkjet printer of FIG. 1 so that the treated solvent stream may be distributed to the print zone of FIG. [Figure 6] 1 illustrates one way that an air baffle can be coupled to the humidification chamber of FIG. 4 and installed in the inkjet printer of FIG. [Figure 7] 1 illustrates an embodiment of a printhead module made up of three printheads, each having a pair of air baffles attached to opposing faces of each printhead. [Figure 8] 4 is a flow diagram for operating the waste disposal system and humidification chamber of the printer. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0010] For a general understanding of the environment for the printer and printer method of operation disclosed herein, as well as the details of the printer and printer method of operation, reference is made to the drawings, in which like reference numbers are used throughout to designate like elements. As used herein, the word "printer" encompasses any device that ejects ink droplets onto different types of media to form ink images.
[0011] 1 depicts a high speed color inkjet printer 10 that processes waste ink generated by a printhead maintenance station and recirculates a solvent stream to the printer's print zone to mitigate nozzle failures in the printer's printhead. As illustrated, the printer 10 includes a media sheet supply S1 Or S 2 1. A printer that forms ink images directly on the surface of a sheet of media removed from one of the printer modules, the sheet S being moved through the printer 10 by a controller 80 that operates one or more of the actuators 40, which are operatively connected to rollers or at least one drive roller of a conveyor 52, which comprises a portion of the media transport 42 that passes through a print zone PZ (shown in FIG. 2) of the printer. In one embodiment, each printhead module has only one printhead having a width corresponding to the width of the widest medium in the cross-process direction that can be printed by the printer. In other embodiments, the printhead modules have multiple printheads, each printhead having a width less than the width of the widest medium in the cross-process direction that the printer can print. In these modules, the printheads are arranged in a staggered printhead array that allows media wider than a single printhead to be printed. Additionally, printheads within or between modules can also be combined such that the density of droplets ejected in the cross-process direction by a printhead can be greater than the minimum spacing between inkjets in a printhead in the cross-process direction. Although printer 10 is depicted with only two media sheet supplies, the printer can be configured with three or more sheet supplies, each containing a different type or size of media.
[0012] The print zone PZ in the printer 10 of FIG. 1 is shown in FIG. 2. The print zone PZ has a length in the process direction equal to the distance from the first inkjet that the sheet passes in the process direction to the last inkjet that the sheet passes in the process direction, and a width that is the maximum distance between the outermost inkjet on either side of the print zone that are directly opposite each other in the cross-process direction. Each printhead module 34A, 34B, 34C, and 34D shown in FIG. 2 has three printheads 204 mounted on one of the printhead carrier plates 316A, 316B, 316C, and 316D, respectively. Adjacent to the print zone PZ are four printhead maintenance stations (PHMs) 32. Periodically, or when image quality metrics indicate that the number of inoperable inkjets in one of the printhead modules exceeds a predetermined threshold, printing operations are stopped and at least the printhead module in which the printhead with an excessive number of inoperable inkjets is located is moved from the print zone PZ to a position opposite the adjacent printhead maintenance station 32. The printhead maintenance station operates to purge ink through the nozzles in the printhead in a known manner. Waste ink generated by one or more purge cycles performed on one or more printheads is collected in a container at the printhead maintenance station. This waste ink is moved to a waste treatment system 304 by a pump 208 or some other type of pneumatic device. The waste treatment system 304 separates the solvent in the waste ink from the solid ink pigment particles so that the solid ink pigment particles from the waste ink received from all of the printhead maintenance stations 32 can be collected in a single container in the system 304 for removal, and the solvent stream is directed to a humidification chamber 308 for further processing, as described in more detail below. As used in this document, the term "print zone" refers to the area of the media transport opposite the printhead of an inkjet printer.
[0013] With further reference to FIG. 1, the printed image exits the print zone PZ and passes under the image dryer 30 after the ink image is printed on the sheet S. The image dryer 30 may include an infrared heater, a heated air blower, an air return, or a combination of these components to heat the ink image to at least partially fix the ink image to the sheet S. The infrared heater applies infrared heat to the printed image on the surface of the sheet S to evaporate water or solvent in the ink. The heated air blower uses a fan, or other pressurized air source, to direct heated air over the ink to supplement the evaporation of water or solvent from the ink. Air is then collected and exhausted by the air return to reduce interference of the dryer airflow with other components in the printer.
[0014] The controller 80 operates at least one of the actuators 40 to rotate the pivot member at position 88 to direct the sheet to either the bin 56 or the return path 72. The rollers rotate the sheet S along the return path 72 in a direction opposite to the process direction movement past the print head. The pivot member 82 is operated by the controller 80 to direct the sheet along a curved portion of the return path 72 into the inverter 76 so that the sheet is flipped over for duplex printing, or along a straight portion of the return path 72. When the sheet follows the straight portion, the inverter 76 is bypassed and the previously printed side of the sheet can be printed again. The controller operates one of the actuators 40 to move the pivot member 82 clockwise to direct the sheet to the inverter 76 or counterclockwise to bypass the inverter. Regardless of whether the substrate has been inverted, the substrate merges into the job stream being carried by the media transport 42 when the controller 80 operates another actuator 40 to rotate the pivot member 86 and provide for the sheet S to enter the job stream from the return path 72.
[0015] As further shown in FIG. 1, the printed media sheets S that are not diverted to the dual path 72 are conveyed by the media transport to the sheet bin 56 where they are collected. Before the printed sheets reach the bin 56, they pass by an optical sensor 84B. The optical sensor 84B generates image data of the printed sheets, which is analyzed by the controller 80 to detect streaks in the printed images on the media sheets of the print job. Additionally, sheets printed with test pattern images are inserted at intervals during the print job. The image data of these test pattern images generated by the optical sensor 84B is analyzed by the controller 80 to determine which inkjets, if any, that were operated to eject ink in the test pattern actually ejected ink, and, if an inkjet ejected an ink drop, whether the ink drop landed with the proper mass and in its intended location. Any inkjet that does not eject the ink drop that it is supposed to eject, or that ejects a drop that does not have the correct mass, or that lands in an incorrect location, is referred to herein as an inoperable inkjet. The controller can store data identifying the inoperable inkjets in a database 92 operatively connected to the controller 80. These sheets with the test pattern printed on them are sometimes referred to as run-time missing inkjet (RTMJ) sheets, and these sheets are discarded from the output of the print job. The user can operate the user interface 50 to obtain a report displayed on the interface identifying the number of inoperable inkjets and the printhead in which they are located. For sheets that are not inverted and are merged into the job stream by the operation of the pivot member 86, the optical sensor 84A generates image data of the printed side, which the controller 80 uses to align the sheet and operate the ejectors in the printheads to print additional images on the previously printed side of the sheet.Optical sensors 84A and 84B may be digital cameras, arrays of LEDs and photodetectors, or other devices configured to generate image data of a passing surface. Although Fig. 1 shows printed sheets being collected in sheet bin 56, the sheets may be directed to other processing stations (not shown) that perform operations such as folding, collating, stitching, and stapling the media sheets.
[0016] The operation and control of the various subsystems, components and functions of the machine or printer 10 is performed with the aid of a controller or electronic subsystem (ESS) 80. The ESS or controller 80 is operatively connected to the printhead modules 34A-34D (and thus the printheads), the actuators 40 and the components of the dryer 30. The ESS or controller 80 is a self-contained computer having, for example, a central processor unit (CPU) with electronic data storage, and a display or user interface (UI) 50. The ESS or controller 80 includes, for example, sensor input and control circuits, as well as pixel arrangement and control circuits. Additionally, the CPU reads, captures, prepares and manages the flow of image data between an image input source, such as a scanning system or an on-line or workstation connection (not shown), and the printhead modules 34A-34D. The ESS or controller 80 is thus the main multitasking processor for operating and controlling all other machine subsystems and functions, including the printing process.
[0017] The controller 80 can be implemented with a general-purpose or dedicated programmable processor that executes program instructions. Instructions and data required to perform the programmed functions can be stored in a non-transitory computer-readable medium associated with the processor or the controller. The processors, their memory, and interface circuits configure the controller to perform the operations described below. These components can be provided on a printed circuit card or as circuits in an application specific integrated circuit (ASIC). Each of the circuits can be implemented in a separate processor, or multiple circuits can be implemented on the same processor. Alternatively, the circuits can be implemented with individual components or circuits provided in a very large scale integrated (VLSI) circuit. The circuits described herein can also be implemented with a combination of processors, ASICs, individual components, or VLSI circuits.
[0018] During operation, image content data for the images to be generated is sent to the controller 80 from either the scanning system or an on-line or workstation connection for processing and generation of printhead control signals that are output to the printhead modules 34A-34D. Along with the image content data, the controller receives print job parameters that identify the weight of the media, the dimensions of the media, the print speed, the type of media, the ink area coverage to be generated on each side of each sheet, the location of the image to be generated on each side of each sheet, the media color, the media fiber orientation for fibrous media, the print zone temperature and humidity, the moisture content of the media, and the media manufacturer. As used in this document, the term "print job parameters" refers to non-image content data for a print job and the term "image content data" refers to digital data that specifies the ink images to be printed on the media sheets.
[0019] 1 includes an air baffle 36 that receives the humidified solvent stream from the humidification chamber 308 and directs the humidified solvent stream to the print zone so that the media transport 42 and the sheet S being carried by the media transport pull the humidified solvent stream through the print zone, increasing humidity in the print zone. The increased humidity helps reduce drying of the ink on the printhead faceplate and in the printhead nozzles, prolonging the operation of the inkjets in the printhead.
[0020] FIG. 3 depicts a waste ink processing system 304. Waste ink 318 is moved into a mixing chamber 320 by air pressure generated by a pneumatic device such as pump 208 (FIG. 2). A member 324 rotated by actuator 40 mixes the incoming waste ink with metal salt received through another port 328. The positive pressure of the incoming waste ink and metal salt pushes a mixed composition 332 of metal salt and waste ink into a settling tank 336 where coagulation interactions between the metal salt and the waste ink form a solvent stream 340, precipitating solid ink pigment particles 344 from the waste ink. These particles 344 fall into a container 352 configured to be removed from the settling tank 336, so that the solid ink pigment particles can be emptied from the container. An air pressure source is fluidly coupled to an exhaust port 348 to allow the solvent stream 340 to be removed from the settling tank 336. The metal salt mixed with the waste ink may be any suitable metal salt that interacts with the solvent of the waste ink to precipitate solid ink pigment particles from the waste ink. Examples of such metal salts are magnesium chloride and calcium chloride for aqueous inks. Other metal salts of sodium, potassium, barium and aluminum may be used to precipitate pigment particles. The air pressure source may be a fan, vacuum, or the like. Although the settling tank has been described as receiving metal salt from a supply of metal salts external to the mixing chamber, a bed of metal salt may be placed within the mixing chamber and refreshed from time to time. As used herein, the term "waste ink treatment system" refers to one or more components configured to separate waste ink into a solvent stream and solid ink pigment particles, and the term "waste ink" refers to ink removed from a printhead that is not used to form a portion of a printed ink image. As used herein, the term "solvent stream" refers to the liquid solvent in the ink after the liquid solvent has been separated from the solid ink pigment particles in the ink by the waste ink treatment system. As used herein, the term settling tank means a partially enclosed volume within a waste ink treatment system where solid ink pigment particles settle from waste ink mixed with metal salts. As used herein, the term "mixing chamber" means a partially enclosed volume where metal salts are mixed with waste ink.
[0021] FIG. 4 depicts a humidification chamber 308 that makes the solvent stream 344 suitable for use in the print zone PZ. The chamber 308 includes a heater 404 and a diffuser 408. The solvent stream 344 enters a space above a water supply 412 in the chamber 308. Heating and agitation of the water by the heater 404 and the diffuser 408, respectively, produces water vapor that mixes with the solvent stream. This humidified solvent stream is pushed or drawn by a pneumatic device 416, such as a fan or vacuum, respectively, into a conduit that is fluidly coupled to an exhaust port 420 that is fluidly connected to the baffle 36. As used herein, the term "humidification chamber" refers to one or more components that are configured to generate water vapor and mix the water vapor with the solvent stream. As used herein, the term "pneumatic device" refers to a device that is configured to push or pull a fluid through a conduit. The heater 404 may be a convection heater, an electrical resistance heater, an infrared heater, an induction heater, or the like. The diffuser may be an ultrasonic or mechanical agitation device.
[0022] FIG. 5 shows an air baffle 36 attached to the leading edge of the printhead 204 in the process direction P so that the humidified solvent flow 344 received from the humidification chamber 308 is directed toward the media transport 42 and the media sheet S being transported by the transport. As used in this document, the term "air baffle" means a structure configured to enclose a volume of air and allow the air to flow from at least one opening at one end of the structure to at least one other opening at the other end of the structure. The media sheet movement and media transport carry the humidified solvent flow past the printhead to inject water and solvent vapor into the printhead environment. The water and solvent vapor help to keep the ink from drying out in the printhead nozzles and on the printhead faceplate. Thus, the operating conditions of the printhead are extended.
[0023] FIG. 6 shows one way that the air baffles coupled to the humidification chamber 308 can be installed in the printer. Rather than attaching a single baffle to the leading face of each printhead in each printhead module, U-shaped clips 604 are used to secure air baffles 36A and 36B to both sides of the printheads in every other printhead module. Baffles 36A and 36B are installed by positioning the U-shaped clips so that the two legs of the clip bias the air baffle against the printhead. Other means of securing the air baffles to both sides of the printheads can be used. Air baffles 36A and 36B are air-coupled to the outlet of the humidification chamber 308 to direct the humidified solvent flow to the print zone of the printer. In one embodiment, the humidified solvent flow exits the air baffle at 1 meter / second. This exit velocity is sufficient for a media transport speed of 1300 mm / second in one embodiment. Of course, the exiting air velocity can be varied to accommodate media transport speeds in other printer embodiments. Figure 7 shows an embodiment of a printhead module 34A configured with three printheads 204, each with a pair of air baffles 36A and 36B attached to opposing faces of each printhead. Arrow P indicates the process direction of the media past printhead assembly 34A. Every other printhead module of Figure 1, i.e., module 34C, is similarly configured.
[0024] A process 800 for operating a waste ink treatment system and humidification chamber of an inkjet printer, in which an air baffle is configured for at least some of the printheads in the printer, is shown in FIG. 8. In the description of the process, a statement that the process performs certain tasks or functions refers to a controller or general-purpose processor executing program instructions stored on a non-transitory computer-readable medium operably connected to the controller or processor to manipulate data or operate one or more components in the printer to perform the tasks or functions. The controller 80 described above can be such a controller or processor. Alternatively, the controller can be implemented with two or more processors and associated circuits and components, each configured to perform one or more tasks or functions described herein. Additionally, the steps of the method can be performed in any feasible chronological order, regardless of the order shown in the figures or the order in which the process is described.
[0025] The process 800 of FIG. 8 begins by detecting the return of at least one printhead module to its printing position after at least one purge cycle has been performed on at least one printhead in at least one printhead module (block 804). The pneumatic device 208 between the waste ink container of the printhead maintenance station and the inlet to the mixing chamber of the waste ink treatment system is activated to drain the waste ink from the printhead maintenance station to the mixing chamber of the waste ink treatment system (block 808). The pressure device is operated to move metal salts into the waste ink in the mixing chamber and activates an actuator that rotates the mixing member (block 812). After a predetermined period of time sufficient to solidify solid ink pigment particles from the waste ink has elapsed (block 816), the pneumatic device is activated to move the resulting solvent stream from the settling tank to the humidification chamber (block 820). A heater and diffuser in the water pool of the humidification chamber are activated to inject water vapor into the solvent stream (block 824). After another predetermined period of time (block 828), the pneumatic device is activated to move the humidified solvent stream into an air baffle attached to the printhead in the printhead module (block 832). After a period of time sufficient to allow the humidified solvent stream generated from the waste ink to be directed to the print zone (block 836), the waste ink treatment system and the devices activated within the humidification chamber are stopped (840).
[0026] To retrofit a printer to operate as described above with respect to FIG. 8, a kit containing a replacement waste ink container for the printhead maintenance station, a waste ink treatment system, a humidification chamber, a supply of metal salts, and three pneumatic devices is provided along with two baffles with U-shaped clips for each printhead of the half of the printhead modules in the printer. The waste container of the printhead maintenance station is removed and a replacement waste ink container is installed in its place. The replacement waste ink container has an outlet port. After the waste ink treatment system and humidification chamber are installed, a conduit with a pneumatic device is installed to connect the replacement waste ink container of the printhead maintenance station to the waste ink treatment system, and a conduit with a pneumatic device is installed to connect the waste ink treatment system to the humidification device. For each printhead in the first printhead module in the process direction and each printhead in every other printhead module thereafter, a baffle is positioned on each side of the printhead in those modules, and a U-shaped clip is positioned so that each leg of the clip rests against the exterior surface of each baffle to compress the baffle against each printhead. Each baffle is fluidly connected to an outlet port of the humidification chamber by a conduit having a pneumatic device. A non-transitory computer readable medium having programmed instructions stored thereon is operatively connected to the controller such that the controller can execute instructions to determine when a printhead maintenance operation is completed and operate the waste ink treatment system and the humidification chamber to inject a humidified solvent flow into the print zone environment.
[0027] It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen substitutions, modifications, variations, or improvements may subsequently be made by those skilled in the art which are also intended to be encompassed by the following claims.
Claims
1. 1. An inkjet printer, comprising: a printhead maintenance station configured to perform at least one purge cycle on at least one printhead in the inkjet printer to generate waste ink; a waste ink treatment system fluidly coupled to the printhead maintenance system to receive the waste ink from the printhead maintenance station, the waste ink treatment system configured to separate the waste ink into solid ink pigment particles and a solvent stream; an inkjet printer comprising: a humidification chamber fluidly coupled to the waste ink treatment system to receive the solvent stream from the waste ink treatment system, the humidification chamber configured to humidify the solvent stream received from the waste ink treatment system and to direct the humidified solvent stream to a print zone of the inkjet printer.
2. The waste ink treatment system comprises: a mixing chamber configured to generate a mixed composition with the waste ink; 10. The inkjet printer of claim 1, further comprising: a settling tank fluidly coupled to the mixing chamber to receive the mixed composition and to allow solid ink pigment particles to settle out of the mixed composition to form the solvent stream.
3. The mixing chamber comprises:
3. The inkjet printer of claim 2, further comprising a member within the mixing chamber configured to rotate to mix the waste ink and metal salts to form the mixed composition.
4. The waste ink treatment system comprises:
4. The inkjet printer of claim 3, further comprising a container configured to be selectively installed within the waste ink treatment system and positioned within the waste ink treatment system to receive the solid ink pigment particles.
5. The humidification chamber comprises: a reservoir configured to hold a volume of water within the humidification chamber; a heater configured to heat the volume of water; 5. The inkjet printer of claim 4, further comprising: a diffuser configured to agitate a water supply, the heated and agitated water supply generating water vapor, the water vapor mixing with the solvent stream to generate a humidified solvent stream.
6. 6. The ink jet printer of claim 5, wherein the heater is one of a convection heater, an electrical resistance heater, an infrared heater, and an induction heater.
7. 6. The ink jet printer of claim 5, wherein the diffuser is an ultrasonic diffuser.
8. a first pneumatic device configured to move waste ink from the print head maintenance station to the mixing chamber of the waste treatment system; a second pneumatic device configured to move the solvent stream from the waste ink treatment system to the humidification chamber; a third pneumatic device configured to move the humidified solvent stream from the humidification chamber to the print zone of the inkjet printer; The inkjet printer of claim 5 further comprising:
9. a first housing positioned in front of at least one print head in the process direction, the first housing fluidly coupled to the humidification chamber for receiving a portion of the humidified solvent flow and for directing the portion of the humidified solvent flow to the print zone of the inkjet printer; The inkjet printer of claim 8 further comprising:
10. a plurality of printhead modules configured to follow one another in the process direction, where all printheads in a first printhead module leading to a configuration of printheads in the process direction have the first housing and a second housing positioned on either side of all printheads in the first printhead module, the second housing being fluidly coupled to the humidification chamber to receive another portion of the humidified solvent stream and to direct the another portion of the humidified solvent stream to the print zone of the inkjet printer; every other printhead module following the first printhead module in the process direction, the every other printhead module having the first housing and the second housing positioned on either side of every printhead in the every other printhead module following the first printhead module in the process direction; The inkjet printer of claim 9 further comprising:
11. 1. A method of operating an inkjet printer, comprising: performing at least one purge cycle on at least one print head in said inkjet printer to generate waste ink; separating the waste ink into solid ink pigment particles and a solvent stream; humidifying the solvent stream; and directing a humidified solvent stream into a print zone of said inkjet printer.
12. directing the humidified solvent stream to a first opening in a first housing positioned at a leading edge of the at least one print head; ejecting the humidified solvent stream through at least one second opening in the first housing to direct the humidified solvent stream toward the print zone of the inkjet printer; The method of claim 11 further comprising:
13. separating the waste ink into the solid ink pigment particles and the solvent stream; 13. The method of claim 12, further comprising: mixing the waste ink with a metal salt to precipitate the solid ink pigment particles from the waste ink, thereby forming a mixed composition.
14. receiving the solid ink pigment particles that precipitate from the mixed composition in a container; The method of claim 13 further comprising:
15. said mixing said waste ink with said metal salt chamber further comprising: The method of claim 14 , further comprising rotating a member with an actuator to mix the metal salt with the waste ink to form the mixed composition.
16. selectively removing said container to discard said solid ink pigment particles; The method of claim 15 further comprising:
17. humidifying the solvent stream by heating and agitating a feed water stream to produce water vapor; 17. The method of claim 16, further comprising mixing the water vapor with the solvent stream to produce a humidified solvent stream.
18. The heating of the feedwater comprises:
20. The method of claim 17, further comprising heating the water supply with one of a convection heater, an electrical resistance heater, an infrared heater, and an induction heater.
19. The stirring of the water supply comprises:
20. The method of claim 18, further comprising agitating the feedwater with an ultrasonic diffuser.
20. directing the humidified solvent stream to a second housing positioned opposite the at least one print head in the process direction; 20. The method of claim 19, further comprising:
21. 1. A kit for retroactively modifying an inkjet printer to separate waste ink into a solvent stream and solid ink pigment particles, and to use the solvent stream to help maintain operational inkjets in a printhead within the inkjet printer, comprising: a replacement waste ink container configured to discharge waste ink from the printhead maintenance station; A waste ink treatment system; A humidification chamber; Three pneumatic devices; two air baffles with U-shaped clips for each printhead equal to half the number of printhead modules in the printer.
22. The waste ink treatment system comprises: a mixing chamber fluidly coupled to the waste ink treatment system and configured to mix the waste ink received from the waste ink treatment system with a metal salt to generate a mixed composition; a settling tank fluidly coupled to the mixing chamber to receive the mixed composition and to allow solid ink pigments to precipitate from the mixed composition to form a solvent stream; 22. The kit of claim 21, further comprising: a container positioned to receive the solid ink pigment particles that settle from the mixed composition in the settling tank.
23. The mixing chamber comprises:
23. The kit of claim 22, further comprising a member within the mixing chamber configured to rotate to mix the waste ink and the metal salt to form the mixed composition.
24. 24. The kit of claim 23, wherein the container of the waste ink treatment system is configured for selective installation within the waste ink treatment system.
25. The humidification chamber comprises: a container configured to hold a volume of liquid within the humidification chamber; a heater configured to heat the container; 25. The kit of claim 24, further comprising a diffuser configured to agitate fluid in the container, the heated and agitated liquid producing a liquid vapor that combines with the solvent stream to produce a humidified solvent stream.
26. 26. The kit of claim 25, wherein the heater is one of a convection heater, an electrical resistance heater, an infrared heater, and an induction heater.
27. 26. The kit of claim 25, wherein the diffuser is an ultrasonic diffuser.
28. A non-transitory computer readable medium having programmed instructions stored thereon, the programmed instructions, when executed by a controller operatively coupled to the non-transitory computer readable medium, operating a first pneumatic device to direct waste ink from a printhead maintenance station to the waste ink treatment system; operating the waste ink treatment system to separate the waste ink into the solid ink pigment particles and the solvent stream; operating a second pneumatic device to direct the solvent flow into the humidification chamber; operating the humidification chamber to humidify the solvent stream; and operating a third pneumatic device to direct the humidified solvent flow into the air baffles held by the U-shaped clips on either side of each printhead of half the number of printhead modules in the inkjet printer.
28. The kit of claim 27.