TEMPERATURE MEASUREMENT IN A HIGH TEMPERATURE FLUID JETTING DEVICE
20190009529 · 2019-01-10
Assignee
Inventors
Cpc classification
B23K3/0623
PERFORMING OPERATIONS; TRANSPORTING
G01K13/02
PHYSICS
B41J2/04563
PERFORMING OPERATIONS; TRANSPORTING
International classification
B41J2/045
PERFORMING OPERATIONS; TRANSPORTING
Abstract
An accurate and compact device for controlling heating of a material in the fluid chamber of a metal droplet jetting device includes a pair of sensors in contact with the material in the fluid chamber. By transmitting a controlled current through the material and detecting the generated voltage across the electrodes (or vice versa), a measure for the resistance of the material is determined. The resistance is temperature-dependent and a good indicator for phase changes in a material. By continually monitoring a resistance related parameter, the heating of the material may be efficiently controlled to maintain the material in its liquid phase during operation.
Claims
1. A device for ejecting droplets of an electrically conductive fluid of a material, the device comprising: a fluid chamber body defining a fluid chamber and having an orifice extending from the fluid chamber to an outer surface of the fluid chamber body; and an actuator for ejecting a droplet of the fluid from the fluid chamber and through the orifice; a controller configured for receiving a signal from a sensor and for determining a temperature parameter of the fluid from the received signal, wherein the sensor is configured for sensing a resistance signal from the fluid and comprises a pair of spaced apart electrodes, wherein said electrodes are: positioned such that fluid is flowable between the electrodes; and arranged for passing an electrical current through fluid between the electrodes.
2. The device according to claim 1, wherein the sensor further comprises a resistance detector connected to the electrodes for sensing a resistance signal representative of the electrical resistance of the fluid between the electrodes.
3. The device according to claim 1, wherein the sensor further comprises: a generator for generating at least one of an electrical current or voltage signal extending between the electrodes; and a detector for sensing at least the other of the electrical current and voltage signal extending between the electrodes, wherein the controller is configured for comparing the generated signal to the sensed signal to determine an electrical resistance parameter of the fluid between the electrodes.
4. The device according to claim 1, wherein the electrodes are positioned on opposite sides of a fluid passage.
5. The device according to claim 1, wherein the actuator comprises at least two electrically conductive actuation electrodes, each actuation electrode being arranged, such that one end of each actuation electrode is in electrical contact with the fluid in the fluid chamber.
6. The device according to claim 5, wherein the electrodes of the sensor are formed by the actuation electrodes.
7. The device according to claim 5, wherein the electrodes are pin-shaped and wherein an electrode is arranged in a through hole in the fluid chamber body, the through hole extending from an outer surface into the fluid chamber.
8. The device according to claim 5, wherein the controller is configured to: transmit an actuation pulse through the electrodes for jetting a droplet of the fluid from the orifice, which actuation pulse comprises a constant current portion; and determining the temperature parameter of the fluid by comparing the constant current portion to a signal portion received in response to the constant current portion.
9. The device according to claim 1, further comprising a heater, wherein the controller is configured to control the heater based on a signal from the sensor to maintain a material in the fluid chamber in a liquid phase.
10. The device according to claim 9, wherein the controller is configured to: receive a first signal from the sensor when a material in a first phase is present in the fluid chamber; control the heater to heat up the material in the fluid chamber; receive a second signal from the sensor when material between the electrodes enters into a second phase; compare the second signal to the first signal to determine a reference resistance parameter; and control the heater by comparing the sensed signal to the reference resistance parameter.
11. The device according to claim 9, wherein the controller is configured to: receive a first signal from the sensor when no material is present between the electrodes; control the heater to heat up the material in the fluid chamber; receive a second signal when fluid from the fluid chamber enters in between the electrodes; compare the second signal to the first signal to determine a reference resistance parameter; and control the heater by comparing the sensed signal to the reference resistance parameter.
12. The device according to claim 11, wherein the sensor further comprises a resistance detector connected to the electrodes for sensing a first and a second resistance signal representative of the electrical resistance of the respectively the solid and liquid phase of the material between the electrodes, and wherein the controller is configured to identify a phase change in the material by comparing the first and second signals.
13. The device according to claim 1, wherein the material of the fluid comprises a metal and wherein the fluid chamber body is arranged in a center of a coil, the coil being configured to carry an electrical current for inducing an inductive current in the material of the fluid for heating the material of the fluid.
14. A printing system comprising the device according to claim 1.
15. A method for determining a temperature of a material in a fluid chamber body of a device for ejecting droplets of an electrically conductive fluid, comprising the steps of: passing an electrical current through material positioned between a pair of electrically conductive electrodes positioned such that the material when in liquid form is flowable between the electrodes; determining a voltage signal between the electrodes; determine a resistance parameter of the material from the voltage and the electrical current; controlling heat supplied to the material in the fluid chamber body by comparing the determined resistance parameter to a reference.
16. The method according to claim 15, further comprising the step of jetting a droplet of the material out of an orifice of the fluid chamber.
17. The method according to claim 16, further comprising the step of applying an actuation pulse to the electrodes for jetting the droplet.
18. The method according to claim 17, further comprising the step of the droplets forming a metallic three-dimensional object on a substrate.
19. The method according to claim 16, wherein the step of controlling heat further comprises maintaining the material in the fluid chamber above its melting point.
20. The method according to claim 19, wherein the step of controlling heat further comprises maintaining the material in the fluid chamber at a temperature above and close to its melting point.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0074] The present invention will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present invention, and wherein:
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[0086] In the drawings, same reference numerals refer to same elements.
[0087] The jetting device 1 is provided with an ejection nozzle 4 through which a droplet of the fluid may be ejected. The nozzle or orifice 4 is a through hole extending through a wall of a fluid chamber body 6. In the fluid chamber body 6 a fluid chamber is arranged. The fluid chamber is configured to hold the fluid. Consequently, the fluid chamber body 6 needs to be heat resistant. Further, the fluid chamber body 6 is made such that the fluid, such as a molten metal, is enabled to flow over a surface, in particular an inner surface of the fluid chamber body 6, the inner surface forming a wall of the fluid chamber. Also, an inner wall of the through hole forming the orifice 4 needs to be wetting for the fluid in order to enable the fluid to flow through the orifice 4. It is noted that this even more relevant compared to known fluid jet devices such as inkjet devices, since molten metals generally have a relatively high surface tension, due to which molten metals tend to form beads. Such beads will generally not flow through a small hole such as the orifice 4. If the surface of the fluid chamber body 6 is wetting with respect to the fluid, the fluid will not tend to form beads, but will easily spread and flow over the surface and is thus enabled to flow into and through the orifice 4.
[0088] The fluid chamber body 6 is replaceably arranged as shown in more detail in e.g.
[0089] For ejecting droplets of molten metal, the jetting device 1 is provided with two permanent magnets 8a, 8b (hereinafter also referred to as magnets 8). The magnets 8 are arranged between two magnetic field concentrating elements 10a, 10b (hereinafter also referred to as concentrators 10) made of magnetic field guiding material such as iron. The jetting device 1 is further provided with two electrodes 12a, 12b (hereinafter also referred to as electrodes 12) both extending into the fluid chamber body 6 through a suitable through hole such that at least a tip of each of the electrodes 12 is in direct electrical contact with the molten metal present in the fluid chamber. The electrodes 12 are supported by suitable electrode supports 14 and are each operatively connected to a suitable electrical current generator (12C in
[0090] The magnets 8 and the concentrators 10 are configured and arranged such that a relatively high magnetic field is obtained at and near the position of the orifice 4, in particular in the molten metal at the location between the two respective tips of the two electrodes 12a, 12b. As indicated in the introductory part hereof, the combination of an electrical current and the magnetic field results in a force exerted on the molten metal, which may result in a droplet of molten metal being pushed through the orifice 4, thereby ejecting a droplet.
[0091] The permanent magnets 8 are thermally isolated from the fluid chamber body 6 at least to the extent that the temperature of the magnets 8 does not exceed a predetermined threshold temperature. This threshold temperature is predetermined based on the temperature above which the magnets 8 may partially or totally lose their magnetization. For example, using permanent magnets 8 made of NdFeB, such a threshold temperature may be about 80 C. In order to achieve such a low temperature, in an embodiment, the magnets 8 may also be actively cooled e.g. using suitable cooling means, such as a cooling liquid.
[0092] The electrodes 12 are made of a suitable material for carrying a relatively high current, while being resistant against high temperatures. The electrodes 12 may be suitably made of tungsten (W), although other suitable materials are contemplated.
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[0094] In an embodiment, at an outer surface, in particular around the orifice 4, the surface is non-wetting for the fluid to be ejected in order to prevent ejection disturbances due to fluid present around the orifice 4. If the above-mentioned wetting coating is also provided at the outer surface, it may be preferable to remove the wetting coating around the orifice 4.
[0095] Further, with reference to
[0096] Now referring to
[0097] In an embodiment the fluid chamber body 6 is made of a material that is heated by inductive heating. As above mentioned, this increases the heating efficiency and in particular decreases a time period needed for melting a metal present in the fluid chamber in a solid state.
[0098] In
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[0100] In order to maintain a fluid tight closure of the electrode passages 36a, 36b, in an embodiment, a spring force is exerted on the electrodes 12, forcing the electrodes 12 into the fluid chamber 16. When the temperature of the fluid chamber body 6 and the electrodes 12 increases during operation, the dimensions of the different parts being made of different materials changes. Using the elastic force, e.g. provided by a spring, it is prevented that any change in diameter of the electrode passages 36a, 36b and any change in diameter of the electrodes 12 may result in leakage of fluid through the electrode passages 36a, 36b. It is noted that such a leakage results in a decrease of the pressure generated by an actuation and thus results in a decreased actuation efficiency.
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[0102] To determine the phase of the material between the electrodes 12a, 12b the controller 40 applies a predefined current to the electrodes 12a, 12b. In consequence, a voltage difference is established between the electrodes 12a, 12b. This voltage difference is detected by means of the voltage detector 12d and transmitted to the controller 40. The voltage generated by the applied current forms a measure for the resistance of the material between the electrodes 12a, 12b. The detected voltage is thus proportional to the resistance of the material. The resistance in turn is dependent on the temperature and/or phase of the material. As such, the voltage is representative of the temperature and/or phase of the material.
[0103] In an advanced example, the controller 40 determines a resistance value from the voltage and the current. The controller 40 then compares the determined resistance to a resistance-temperature curve or table for the applied material stored on its memory. Thereby, a value indication of temperature of the material may be obtained.
[0104] Optionally, the controller 40 may analyze the received voltage signal, for example by comparing the voltage to the current to determine a resistance or resistance of the material between the electrodes 12a, 12b. The controller 40 compares the received voltage signal to a reference stored on the memory of the controller 40. The reference may be a predetermined reference voltage corresponding to the melting point of the material in the fluid chamber 16. The reference may be selected from a look-up table on stored the memory using a material type input by an operator. Alternatively, the controller 40 may determine the reference during the heating process, as will be explained for
[0105] Based on the comparison between the received signal and the stored reference, the controller 40 controls the induction generator 18a to transmit an alternating current through the induction coil 18. Preferably, the reference corresponds to a phase transition of the material, and the controller 40 controls the heater 18, 18a to maintain the material in the liquid phase. Control of the coil induction generator 18a may be done based on any known feedback mechanism, such as a feedback loop based on a difference between the reference and the detected voltage. In a basic example, the controller 40 determines a phase transition from the received voltage signal and maintains the inductive heating at its power level or value at the time of detecting the phase transition. Thereby, the present invention provides a single yet accurate control mechanism for maintaining the material in the fluid chamber 16 in a liquid state. The voltage detected by the sensor 42 thus provides an accurate measure which can be used to control the heater 18 to keep the material in a liquid state.
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[0109] The method starts with the initial step of the controller 40 activating the heater 18 to heat the material M in the fluid chamber 16. An alternating current is transmitted from the coil induction generator 18a to the coil 18 to inductively heat the material. During heating, the controller 40 receives data from the sensor 42. The current generator 12c transmits a current to the electrodes 12a, 12b while the voltage detector 12d monitors the voltage across the electrodes 12a, 12b. Initially there may be no material M present between the electrodes 12a, 12b as explained with reference to
[0110] The lower block represents the heater control operation of the device according to the present invention. First a suitable reference is selected, either via the above described methods or from a reference-material type table stored on the controller 40. The controller 40 then continually or intermittently receives the resistance signal V from the sensor 42. The received resistance signal V is compared to the reference. Thereby, the phase of the material M may be determined. Further, the controller 40 may determine whether additional heating by the heater 18 is required. The coil current generated by the coil induction generator 18a is thus controlled by comparing the resistance signal V to the reference.
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[0112] A suitable material for the electrically isolating and thermally conductive body 24 may be aluminum-nitride (AlN).
[0113] The spring 20 is connected to a coupling element 38, the coupling element 38 further being connected to the electrode 12b. Thus, the spring 20 is enabled to exert its spring force on the electrode 12b through the coupling element 38. The coupling element 38 may further be employed to provide a suitable electrical coupling to the current generator, e.g. using an electrical conductive wire 22.
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[0117] Detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. In particular, features presented and described in separate dependent claims may be applied in combination and any combination of such claims are herewith disclosed.
[0118] Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. The terms a or an, as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language). The term coupled, as used herein, is defined as connected, although not necessarily directly.