Resonance behavior of a compliant piezo-driven inkjet channel with an entrained microbubble.

Microbubbles entrained in a piezo-driven drop-on-demand printhead disturb the acoustics of the microfluidic ink channel and, thereby, the jetting behavior. Here, the resonance behavior of an ink channel as a function of the microbubble size and number of bubbles is studied through theoretical modeling and experiments. The system is modeled as a set of two coupled harmonic oscillators: one corresponds to the compliant ink channel and the other corresponds to the microbubble. The predicted and measured eigenfrequencies are in excellent agreement. It was found that the resonance frequency is independent of the bubble size as long as the compliance of the bubble dominates over that of the piezo actuator. An accurate description of the eigenfrequency of the coupled system requires the inclusion of the increased inertance of the entrained microbubble due to confinement. It is shown that the inertance of a confined bubble can be accurately obtained by using a simple potential flow approach. The model is further validated by the excellent agreement between the modeled and measured microbubble resonance curves. The present work, therefore, provides physical insight into the coupled dynamics of a compliant ink channel with an entrained microbubble.

Regimes of bubble volume oscillations in a pipe.

The effect of an acoustically driven bubble on the acoustics of a liquid-filled pipe is theoretically analyzed and the dimensionless groups of the problem are identified. The different regimes of bubble volume oscillations are predicted theoretically with these dimensionless groups. Three main regimes can be identified: (1) For small bubbles and weak driving, the effect of the bubble oscillations on the acoustic field can be neglected. (2) For larger bubbles and still small driving, the bubble affects the acoustic field, but due to the small driving, a linear theory is sufficient. (3) For large bubbles and large driving, the two-way coupling between the bubble and the flow dynamics requires the solution of the full nonlinear problem. The developed theory is then applied to an air bubble in a channel of an inkjet printhead. A numerical model is developed to test the predictions of the theoretical analysis. The Rayleigh-Plesset equation is extended to include the influence of the bubble volume oscillations on the acoustic field and vice versa. This modified Rayleigh-Plesset equation is coupled to a channel acoustics calculation and a Navier-Stokes solver for the flow in the nozzle. The numerical simulations indeed confirm the predictions of the theoretical analysis.

Acoustic measurement of bubble size in an inkjet printhead.

The volume of a bubble in a piezoinkjet printhead is measured acoustically. The method is based on a numerical model of the investigated system. The piezo not only drives the system but it is also used as a sensor by measuring the current it generates. The numerical model is used to predict this current for a given bubble volume. The inverse problem is to infer the bubble volume from an experimentally obtained piezocurrent. By solving this inverse problem, the size and position of the bubble can thus be measured acoustically. The method is experimentally validated with an inkjet printhead that is augmented with a glass connection channel, through which the bubble was observed optically, while at the same time the piezocurrent was measured. The results from the acoustical measurement method correspond closely to the results from the optical measurement.

Effect of an entrained air bubble on the acoustics of an ink channel.

Piezo-driven inkjet systems are very sensitive to air entrapment. The entrapped air bubbles grow by rectified diffusion in the ink channel and finally result in nozzle failure. Experimental results on the dynamics of fully grown air bubbles are presented. It is found that the bubble counteracts the pressure buildup necessary for the droplet formation. The channel acoustics and the air bubble dynamics are modeled. For good agreement with the experimental data it is crucial to include the confined geometry into the model: The air bubble acts back on the acoustic field in the channel and thus on its own dynamics. This two-way coupling limits further bubble growth and thus determines the saturation size of the bubble.