IP Library › Granted Patent US 11,654,482
Granted Patent B2
US 11,654,482 · App. 17/367,991 · Granted May 23, 2023

Liquid metal ejector level sensing system and methods thereof

Inventors: Joseph C. Sheflin (Macedon, NY); Jason M. LeFevre (Penfield, NY)
Assignee: XEROX CORPORATION
B22D46/00B22D23/003B33Y10/00B33Y50/02
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Quick Facts
Patent No.
US 11,654,482
App. No.
17/367,991
Filed
Jul 6, 2021
Granted
May 23, 2023
Kind
B2
Art Unit
3726
USPC
419/PCA.001
Abstract

A method of controlling sensing level in a liquid ejector is disclosed. The method includes filling a reservoir in communication with a liquid ejector with a printing material to a first level set point, receiving a drop out signal from a laser-based level sensor that reads from a surface of a melt pool in the reservoir, pausing an operation of the liquid ejector, adjusting the printing material level set point to a second level set point of printing material in reservoir that is higher than the first level set point, increasing a quantity of printing material in the reservoir to fill the reservoir to the second level set point, and resuming the operation of the liquid ejector.

Claims (33)

1. A method of controlling sensing level in a liquid ejector, comprising:

(a) filling a reservoir in communication with a liquid ejector with a printing material to a first level set point;

(b) receiving a drop out signal from a laser-based level sensor that reads from a surface of a melt pool in the reservoir;

(c) pausing an operation of the liquid ejector;

(d) adjusting the printing material level set point to a second level set point of printing material in reservoir that is higher than the first level set point;

(e) increasing a quantity of printing material in the reservoir to fill the reservoir to the second level set point;

(f) confirming an absence of the drop out signal from the laser-based level sensor after filling the reservoir with the printing material to the second level set point; and

(g) resuming the operation of the liquid ejector; and

wherein the drop out signal comprises an erroneous signal from the laser-based level sensor reading scattering of light caused by contamination on the surface of the melt pool in the reservoir.

2. The method of controlling sensing level in a liquid ejector of claim 1 , wherein the printing material comprises metal, metallic alloys, or a combination thereof.

3. The method of controlling sensing level in a liquid ejector of claim 1 , wherein the printing material comprises aluminum, aluminum alloys, or a combination thereof.

4. The method of controlling sensing level in a liquid ejector of claim 1 , wherein the printing material is a powder.

5. The method of controlling sensing level in a liquid ejector of claim 1 , wherein the second level set point comprises from about 2 mm to about 4 mm relative to the first level set point.

6. The method of controlling sensing level in a liquid ejector of claim 1 , further comprising:

adjusting the printing material level set point to a third level set point of printing material in reservoir that is higher than the second level set point; and

increasing the quantity of printing material in the reservoir to fill the reservoir to the third level set point.

7. The method of controlling sensing level in a liquid ejector of claim 1 , further comprising repeating steps (a) through (g).

8. The method of controlling sensing level in a liquid ejector of claim 1 , wherein the printing material is in the form of a wire feed.

9. The method of controlling sensing level in a liquid ejector of claim 2 , further comprising removing the printing material wire feed from the reservoir.

10. The method of controlling sensing level in a liquid ejector of claim 1 , further comprising determining a maximum melt pool height prior to filling the reservoir with the printing material to the first level set point.

11. The method of controlling sensing level in a liquid ejector of claim 7 , wherein the maximum melt pool height is higher than the first level set point and the second level set point.

12. The method of controlling sensing level in a liquid ejector of claim 9 , wherein the first level set point is from about 4 mm to about 8 mm lower than the maximum melt pool height.

13. A method of controlling sensing level in a liquid ejector, comprising:

(a) filling a reservoir in communication with a liquid ejector with a printing material to a first level set point;

(b) receiving a drop out signal from a laser-based level sensor that reads from a surface of a melt pool in the reservoir;

(c) pausing an operation of the liquid ejector;

(d) adjusting the printing material level set point to a second level set point of printing material in reservoir that is higher than the first level set point;

(e) increasing a quantity of printing material in the reservoir to fill the reservoir to the second level set point;

(f) confirming an absence of the drop out signal from the laser-based level sensor after filling the reservoir with the printing material to the second level set point; and

(g) resuming the operation of the liquid ejector; and

wherein the printing material comprises a wire feed comprising a metal, a metallic alloy, or a combination thereof; and

wherein the drop out signal comprises an erroneous signal from the laser-based level sensor reading scattering of light caused by contamination on the surface of the melt pool in the reservoir.

14. The method of sensing level in a liquid ejector of claim 13 , further comprising repeating steps (a) through (g).