FLUID DETECTION CIRCUIT FOR FLUID EJECTION HEAD

Abstract

A fluid ejection head and a method of detecting the presence of fluid in an ejection chamber. The ejection head includes a semiconductor substrate having an elongate fluid supply via etched therethrough. An array of fluid ejectors is disposed adjacent to the fluid supply via, wherein the elongate fluid supply via provides fluid to the array of fluid ejectors for ejection of fluid from the ejection head. Fluid sense cells for the array of fluid ejectors are disposed at each end of the fluid supply via, wherein each of the fluid sense cells has a fluid ejector, an electrode disposed in a fluid chamber for the fluid ejector, and an electrode disposed in a fluid channel associated with a fluid chamber. A fluid detection circuit is provided in electrical communication with each of the fluid sense cells for detecting the presence or absence of fluid in the fluid chamber.

Claims

1. A fluid ejection head comprising: a semiconductor substrate having an elongate fluid supply via etched therethrough; an array of fluid ejectors disposed adjacent to the fluid supply via, wherein the elongate fluid supply via provides fluid to the array of fluid ejectors for ejection of fluid from the ejection head; fluid sense cells for the array of fluid ejectors disposed at each end of the fluid supply via, wherein each of the fluid sense cells has a fluid ejector, an electrode disposed in a fluid chamber for the fluid ejector, and an electrode disposed in a fluid channel associated with a fluid chamber; and a fluid detection circuit in electrical communication with each of the fluid sense cells for detecting the presence or absence of fluid in the fluid chamber.

2. The fluid ejection head of claim 1, wherein the fluid detection circuit generates a bit having a value indicative of the presence or absence of fluid in the fluid chamber.

3. The fluid ejection head of claim 2, further comprising a digital circuit having multiple stages for receiving bits in parallel and shifting bits out in series to an ejection head controller, wherein each of the multiple stages receives a bit generated by the fluid detection circuit.

4. The fluid ejection head of claim 3, wherein the digital circuit comprises a parallel-in/serial-out shift register.

5. The fluid ejection head of claim 1, wherein each of the fluid sense cells comprise a conductivity sense circuit, wherein the conductivity sense circuit provides a digital high output when fluid is detected in the fluid channel and the fluid chamber and a digital low output when fluid is absent from the fluid chamber.

6. A digital dispense system comprising: a pipette fillable cartridge having a fluid containing chamber therein and the fluid ejection head of claim 1 is attached to the pipette fillable cartridge, wherein the array of fluid ejectors is in fluid flow communication with the fluid containing chamber; and a controller for controlling ejection of fluid from the fluid ejection head.

7. A fluid ejection head comprising: at least two fluid supply vias etched through a semiconductor substrate for providing fluid to an array of fluid ejectors disposed adjacent to each of the at least two fluid supply vias, wherein each fluid ejector of the array of fluid ejectors has a fluid channel for directing fluid from each of the at least two fluid supply vias to a fluid chamber for ejection by the fluid ejection head; a fluid sense cell having a first electrode disposed in the fluid channel and a second electrode attached to a fluid ejector in the fluid chamber associated with the fluid channel for each of the at least two fluid supply vias, wherein the fluid sense cell is disposed at a proximal end of each of the at least two fluid supply vias; and a fluid detection circuit in electrical communication with the fluid sense cell for detecting the presence or absence of fluid in the fluid chamber.

8. The fluid ejection head of claim 7, wherein the fluid detection circuit generates a bit having a value indicative of the presence or absence of fluid in the fluid chamber.

9. The fluid ejection head of claim 8, further comprising a digital circuit having multiple stages for receiving bits in parallel and shifting bits out in series to an ejection head controller, wherein each of the multiple stages receives a bit generated by the fluid detection circuit.

10. The fluid ejection head of claim 9, wherein the digital circuit comprises a parallel-in/serial-out shift register.

11. The fluid ejection head of claim 7, further comprising a second fluid sense cell, wherein the second fluid sense cell is disposed on a distal end of each array of fluid ejectors.

12. The fluid ejection head of claim 7, wherein the fluid ejection head comprises at least three fluid supply vias, a fluid ejector array for each of the three fluid supply vias, and a fluid detection circuit for each fluid ejector array.

13. The fluid ejection head of claim 7, wherein the fluid ejection head comprises at least four fluid supply vias, a fluid ejector array for each of the four fluid supply vias, and a fluid detection circuit for each fluid ejector array.

14. The fluid ejection head of claim 7, wherein the fluid ejection head comprises at least six fluid supply vias, a fluid ejector array for each of the six fluid supply vias, and a fluid detection circuit for each fluid ejector array.

15. A method for detecting the presence or absence of fluid in a fluid chamber of a fluid ejection head, the method comprising: providing a fluid ejection head and an ejection head controller therefor, the fluid ejection head having: a semiconductor substrate having at least one elongate fluid supply via etched therethrough; an array of fluid ejectors disposed adjacent to the at least one elongate fluid supply via, wherein the elongate fluid supply via provides fluid to the array of fluid ejectors for ejection of fluid from the ejection head; a fluid sense cell for the array of fluid ejectors disposed at a proximal end of the at least one elongate fluid supply via, wherein the fluid sense cell has a fluid ejector, a first electrode disposed in a fluid chamber for the fluid ejector, and a second electrode disposed in a fluid channel associated with a fluid chamber; a fluid detection circuit in electrical communication with the fluid sense cell for detecting the presence or absence of fluid in the fluid chamber; applying a bias voltage to each of the first and second electrodes of the fluid sense cell; removing the bias voltage from the second electrode; capturing a current pulse in the fluid detection circuit upon removal of the bias voltage from the second electrode; and comparing the current pulse to a reference current in the fluid detection circuit, wherein the fluid detection circuit outputs a digital signal to an ejection head controller.

16. The method of claim 15, wherein the fluid sense cell comprises a conductivity sense circuit, and the fluid detection circuit provides a digital high output bit when fluid is detected in the fluid channel and the fluid chamber and provides a digital low output bit when fluid is absent from the fluid chamber.

17. The method of claim 16, further comprising receiving the digital high output bit or digital low output bit in a digital circuit having multiple stages for receiving bits in parallel and shifting bits out in series to the ejection head controller, wherein each of the multiple stages receives a bit generated by the fluid detection circuit.

18. The method of claim 15, wherein the ejection head controller terminates fluid ejection from each fluid ejector array when the fluid detection circuit signals the absence of fluid.

19. The method of claim 15, wherein the fluid ejection head comprises a latch circuit for the fluid detection circuit for holding a digital bit from each fluid detection circuit for transfer to a shift register.

20. The method of claim 15, wherein a second fluid sense cell for the array of fluid ejectors is disposed on a distal end of the at least one elongate fluid supply via.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0019] FIG. 1 is a perspective view, not to scale, of a digital dispense system according to an embodiment of the disclosure.

[0020] FIG. 2 is a perspective view, not to scale, of a tray and microwell plate for use with the digital dispense system of FIG. 1.

[0021] FIG. 3 is a perspective view, not to scale, of a pipette-Tillable cartridge for use with the digital dispense system of FIG. 1.

[0022] FIG. 4 is a plan view, not to scale, of an ejection head for the pipette-fillable cartridge of FIG. 3.

[0023] FIG. 5 is an enlarged plan view, not to scale of a portion of an ejector array on the ejection head of FIG. 4.

[0024] FIGS. 6 and 7 are schematic views not to scale of a fluid sensor for a fluid detection circuit without and with fluid according to an embodiment of the disclosure.

[0025] FIG. 8 is a schematic diagram of the fluid sensor of FIGS. 6 and 7.

[0026] FIG. 9 is schematic plan view, not to scale, of an ejection head according to one embodiment of the disclosure.

[0027] FIG. 10 is schematic plan view, not to scale, of an ejection head according to a second embodiment of the disclosure.

[0028] FIG. 11 is schematic plan view, not to scale, of an ejection head according to a third embodiment of the disclosure.

[0029] FIG. 12 is a schematic plan view, not to scale, of an ejection head according to a fourth embodiment of the disclosure.

[0030] FIG. 13 is a schematic plan view, not to scale, of an ejection head according to a fifth embodiment of the disclosure.

[0031] FIG. 14 is a schematic illustration of a fluid ejection head containing a fluid detection circuit according to an embodiment of the disclosure.

[0032] FIG. 15 is a process flow diagram for the fluid detection circuit of FIG. 12 according to embodiments of the disclosure.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0033] With reference to FIGS. 1-2 there is shown a digital dispense device 10 for accurately dispensing an amount of one or more fluids onto a substrate. The device 10 has an ejection head that moves back and forth in a first x direction and a tray 14 for moving a substrate that moves back and forth in a second y direction orthogonal to the first direction during the fluid dispense operation. The tray 14 is adaptable to a wide variety of substrates including, but not limited to, micro-well plates, glass slides, electronic circuit boards and the like. FIG. 2 illustrates a tray 14 for holding a micro-well plate 38 containing wells 40 therein for use with the digital dispense device 10 to dispense fluid into the wells 40 of the micro-well plate or onto the glass slides. The tray 14 may include adapters for different size micro-well plates or for holding slides or other substrates for deposit of fluid thereon.

[0034] The dispense head cartridge containing a fluid ejection head and a cartridge movement mechanism are contained in a rectangular prism-shaped box 18. An activation switch 20 is included on the box 18 for activating the device 10. A rear side of the box 18 includes an opening for movement of the tray 14 through the box 18 in the second direction to dispense fluid onto a substrate. A USB port is provided on the box 18 to connect the digital dispense system 10 to a computer or a digital display device. Power is provided to the system 10 through a power input port on the box 18.

[0035] In some embodiments, a pipette-fillable cartridge 50 for use with the digital dispense device 10 of FIG. 1 is illustrated in FIG. 3. In other embodiments, a conventional fluid cartridge is used. The pipette-fillable cartridge 50 has a molded body 52 that provides one or more open fluid holding chambers 54a-54f therein. The fluid holding chambers 54a-54f are separated from one another by dividing walls 56A and 56B. Each of the fluid holding chambers 54a-54f is associated with a fluid supply via on an ejection head. With reference to FIG. 4, an ejection head 60 containing six fluid supply vias 62 is shown. Each of the fluid supply vias 62 is associated with an array of fluid ejectors that may be disposed on one or both sides of the fluid supply vias 62, as described in more detail below. A greatly magnified portion of the ejection head 60 is illustrated in more detail in FIG. 5. Each fluid supply via 62 provides fluid from one of the fluid holding chambers 54a-54f to arrays of fluid ejectors 64 disposed on one or both sides of the fluid supply via 62. The fluid ejectors are located in a fluid chamber 66. Fluid is provided from the fluid supply via 62 through a fluid channel 68 to the fluid chamber 66. Upon activation of the fluid ejector 64, fluid is dispensed through an ejection nozzle 70 to a substrate which may be the well 40 of the micro-well plate 38 or to a glass slide.

[0036] In order to determine if the fluid chambers 66 of the ejection head 60 contain fluid, a fluid detection circuit containing a fluid sense circuit may be used. The fluid sense circuit may be a conductivity detection device 80 as illustrated in a simplified plan view in FIG. 6 of a single fluid chamber 66 containing electrodes 82 and 84. Electrode 82 may be a tantalum protective layer disposed over the fluid ejector 64. A second electrode 84 is disposed in the fluid channel 68 for contact with fluid flowing from the fluid supply via 62 to the fluid ejection chamber 66. Each of the electrodes 82 and 84 may be made of a metal such as tantalum which is resistant to the fluids dispensed by the digital dispense device 10. Accordingly, any suitable metal may be used as electrodes 82 and 84.

[0037] FIG. 7 shows the conductivity detection device 80 in a steady state with the fluid chamber 66 and fluid channel 68 filled with fluid 86. As shown, the first electrode 82 and second electrode 84 are now fluidly connected by means of a conductive fluid 86. It is known from electrochemical principles that the relationship between the fluid and the first and second electrodes 83 and 84 can be represented by an electrical circuit 90 with a resistor, Rs, representing the solution resistance and the capacitor, Cd, representing the double layer capacitance formed at the electrode to fluid interface when biased as shown in FIG. 8. It should be understood that in the case where a conductive liquid is not present the double layer capacitor does not exist, and the series resistance would appear as an open circuit.

[0038] While the foregoing conductivity detection device 80 may be applied to all of the fluid ejectors in an array of fluid ejectors 64, a single conductivity detection device 80 may be used for each array of fluid ejectors 64. Accordingly, if fluid is not sensed by the conductivity detection device 80 for a single array of fluid ejectors, activation of all fluid ejectors for a single fluid supply via 62 may be terminated.

[0039] FIGS. 9-13 are schematic illustrations of ejection heads containing multiple fluid supply vias, fluid ejectors associated with the fluid supply vias, and fluid sense circuits. FIG. 9 illustrates a fluid ejection head 100 containing arrays of fluid ejectors 102a and 102b disposed on both sides of an elongate fluid supply via 104. With relatively long fluid supply via 104, it may be useful to provide a fluid sense circuit for the fluid ejectors at a proximal end and at a distal end of the fluid supply via 104 as shown by the shaded squares. Accordingly, only fluid ejectors 106 and 108 will contain the electrodes 82 and 84 described above while the remaining fluid ejectors 118 (represented by the open squares) will be devoid of the electrodes 82 and 84.

[0040] In some embodiments, there are multiple fluid supply vias and only a single fluid sense circuit is used for each fluid supply via. For Example, FIG. 10 illustrates an ejection head 200 having fluid ejector arrays 202a, 202b, 202c, and 202d disposed on opposing sides of fluid supply vias 204a and 204b. In this embodiment, only fluid ejectors 206 and 208 (shaded squares) for each of the fluid supply vias 204a and 204b contain the fluid detection electrodes 82 and 84 and the remaining fluid ejectors 210 (open squares) are devoid of the fluid detection electrodes.

[0041] In some embodiments, the ejection head has multiple elongate fluid supply vias. FIG. 11 illustrates an ejection head 300 having ejector arrays 302a, 302b, and 302c disposed on only one side of elongate fluid supply vias 304a, 304b, and 304c, respectively. In this embodiment, only fluid ejectors 306, 308, 310, 312, 314, and 316 (shaded squares) contain the fluid detection electrodes 82 and 84 while the remaining fluid ejectors 318 (open squares) are devoid of the fluid detection electrodes.

[0042] In some embodiments, as illustrated in FIG. 12, the ejection head contains ejector arrays 402a, 402b, 402c, 402d, 402e, 402f, 402g, and 402h disposed on opposing sides of four fluid supply vias 404a, 404b, 404c, and 404d. In this embodiments, only one fluid ejector (406, 408, 410 and 412) for each of the fluid supply vias 404a-404d contains the fluid detection electrodes 82 and 84. The other fluid ejectors 416 are devoid of the fluid detection electrodes.

[0043] FIG. 13 illustrates another fluid ejection head 500 having six fluid supply vias 504a, 504b, 504c, 504d, 504e and 504f, having a single ejector array 502a, 502b, 502c, 502d, 502e, and 502f for each of the fluid supply vias. Each ejector array contains a fluid sense cell 506, 508, 510, 512, 514, and 516 (shaded cells) having the fluid detection electrodes 82 and 84. The other fluid ejectors 518 are devoid of fluid sense cells.

[0044] In the embodiments illustrated in FIGS. 9-13, it is assumed that if a fluid ejector containing the fluid detection electrodes indicates the presence of fluid in the fluid chamber, then all of the fluid chambers in the same fluid ejector array are assumed to have fluid and thus are primed for ejection of fluid. However, if no fluid is detected by the fluid ejector containing the fluid detection electrodes, then it is assumed that none of the fluid chambers in the same fluid ejector array are primed for fluid ejection. In some embodiments, the fluid ejector containing the fluid detection electrodes is placed at one end of the fluid supply via. In other embodiments, the fluid ejector containing the fluid detection electrodes is placed at both ends of the fluid supply via. Thus, it is possible to determine if the fluid chambers in a fluid ejector array are primed for fluid ejection by using a minimal number of fluid detection devices and circuits therefor. The placement and number of fluid sense cells used will depend on the length of the fluid supply vias and the number of fluid supply vias in the ejection head.

[0045] FIG. 14 is a schematic illustration of a fluid ejection head 600 containing multiple fluid supply vias and multiple fluid detection circuits for the multiple fluid supply vias. Each fluid detection circuit 602 is associated with a fluid channel electrode 604, a fluid chamber electrode 606, and a latch circuit 608. The fluid channel electrode 604 is disposed in the fluid channel 610 that provides fluid from a fluid supply via to the fluid chamber 612 containing a fluid ejector 614. The fluid channel electrode 604 is in electrical communication with the fluid detection circuit 602 as shown. The fluid chamber electrode 606 is also in electrical communication with the fluid detection circuit 602 such that the presence of fluid across both electrodes can be detected by the fluid detection circuit 602. A digital output from the fluid detection circuit 602 is transferred to a latch circuit 608 so that the fluid detection circuit 602 can resample the fluid channel electrode 604 and fluid chamber electrode 606 without losing the previously generated output. The latch circuit 608 transfers the output values from the fluid detection circuit 602 to a digital circuit (such as a shift register 618) having multiple stages for receiving bits in parallel and shifting bits out in series to an ejection head controller 620, wherein each of the multiple stages receives a bit generated by the fluid detection circuit. Accordingly, as shown in FIG. 14 all digital outputs from the latch circuits on the ejection head are transferred in parallel to a different selected bit of the shift register 618. The bits B.sub.0 to B.sub.n of the shift register are output from the ejection head to a device controller 620 through an output pad 622 on the ejection head 600.

[0046] FIG. 13 is an illustrative block flow diagram 700 for using the fluid detection circuit of FIG. 14 to determine if fluid is present in the fluid chambers of an ejection head. In the first step 702 of the process, a low duration current pulse may be generated by applying 0.9 volts to each of the channel electrode 604 and fluid chamber electrode 606 and then setting the voltage on the fluid chamber electrode to 0 volts in step 704 to generate a low duration current pulse in step 706. The fluid detection circuit 602 will sample the current generated by the change in voltage between the channel electrode 604 and fluid chamber electrode 606 and compare the magnitude of the current to a reference current in step 708. If the current pulse is greater than the reference current, the fluid detection circuit 602 will output a logical high value in step 710. Otherwise, the output from the fluid detection circuit 602 will remain at a logical low state in step 712. The output from the fluid detection circuit 602 is transferred to a latch circuit 608 in step 714. The latch circuit 608 for each of the fluid detection circuits 602 transfers the outputs in parallel to selected bits of a shift register 618 in step 716 so that the bias voltage from the chamber electrodes can be removed in step 718. The bits in the shift register 618 are output serially to the device controller 620 in step 720. If the controller 620 detects that fluid is present in the fluid chamber 612 of the ejection head 600, then all of the fluid ejectors on the ejection head 600 associated with the fluid supply via where fluid is detected by the fluid detection circuit 602 can be activated for ejecting fluid. If no fluid is detected by the fluid detection circuit 602, it is assumed that the fluid chambers 612 associated with the fluid detection circuit 602 and fluid supply via are not primed and thus the fluid ejectors 614 in the fluid ejector array will not be activated until the fluid chamber 612 associated with the fluid detection circuit 602 detects the presence of fluid.

[0047] While the foregoing description provides a fluid detection circuit that uses fluid conductivity, the foregoing may also be adapted to a fluid detection circuit that is suitable for non-conductive fluids. In that case, a backup fluid detection circuit may also be included on the ejection head. The backup fluid detection circuit is provided where the fluid ejectors are thermal fluid ejectors that are used to heat the fluid and create a vapor bubble in the fluid chamber. The formation of a bubble on a surface of the thermal fluid ejector is detected based on the slope change in the current passing through the fluid ejector. If no fluid is present on the surface of the thermal fluid ejector, the rate at which the surface of the fluid ejector is heated will increase. By detecting a change in the rate of heating of the ejector surface, the presence or absence of fluid in the fluid chamber can be detected.

[0048] It will be appreciated that the foregoing description provides a system and method for minimizing the number of fluid sensors required to determine if fluid is present in the fluid chambers of an ejector array. The fluid sensors are compatible with multiple arrangements of fluid supply vias and the fluid detection circuit can activate all of the fluid sensors in parallel while serially reading the states of the fluid sensors. Since the number of sensors is minimized, the time required to determine if the fluid chambers are primed with fluid is also minimized.

[0049] It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.

[0050] While particular embodiments have been described, alternatives, modifications, variations, improvements, and substantial equivalents that are or can be presently unforeseen can arise to applicants or others skilled in the art. Accordingly, the appended claims as filed and as they can be amended are intended to embrace all such alternatives, modifications variations, improvements, and substantial equivalents.