U.S. patent application number 12/436127 was filed with the patent office on 2009-08-27 for inkjet printhead having adhered ink distribution structure.
This patent application is currently assigned to Silverbrook Research Pty Ltd. Invention is credited to Norman Micheal Berry, Christopher Hibbard, Garry Raymond Jackson, Paul Ian Mackey, Akira Nakazawa, Kia Silverbrook.
Application Number | 20090213176 12/436127 |
Document ID | / |
Family ID | 34749937 |
Filed Date | 2009-08-27 |
United States Patent
Application |
20090213176 |
Kind Code |
A1 |
Silverbrook; Kia ; et
al. |
August 27, 2009 |
Inkjet Printhead Having Adhered Ink Distribution Structure
Abstract
An inkjet printhead is provided having an integrated circuit
having a plurality of inkjet nozzles formed on one surface and a
plurality of ink delivery channels formed on an opposing surface
for delivering ink to the nozzles, an ink distribution member
having a plurality of conduits formed therethrough which each have
an inlet for receiving ink from an ink supply and an outlet for
distributing the received ink to the ink delivery channels of the
integrated circuit, and an adhesive layer adhering the integrated
circuit to the ink distribution member. The adhesive layer has a
plurality of holes aligned with corresponding ones of the outlets
and delivery channels so that ink can be supplied therebetween.
Inventors: |
Silverbrook; Kia; (Balmain,
AU) ; Nakazawa; Akira; (Balmain, AU) ;
Hibbard; Christopher; (Balmain, AU) ; Mackey; Paul
Ian; (Balmain, AU) ; Berry; Norman Micheal;
(Balmain, AU) ; Jackson; Garry Raymond; (Balmain,
AU) |
Correspondence
Address: |
SILVERBROOK RESEARCH PTY LTD
393 DARLING STREET
BALMAIN
2041
AU
|
Assignee: |
Silverbrook Research Pty
Ltd
|
Family ID: |
34749937 |
Appl. No.: |
12/436127 |
Filed: |
May 6, 2009 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11014762 |
Dec 20, 2004 |
7537309 |
|
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12436127 |
|
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10760254 |
Jan 21, 2004 |
7448734 |
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11014762 |
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Current U.S.
Class: |
347/40 ;
347/85 |
Current CPC
Class: |
B41J 2/14427 20130101;
B41J 2/16526 20130101; B41J 2/19 20130101; B41J 2002/14459
20130101; B41J 2/04541 20130101; B41J 2/04543 20130101; B41J
2/17503 20130101; B41J 2/04585 20130101; B41J 2/155 20130101; B41J
29/02 20130101; B41J 2/1634 20130101; B41J 2002/14491 20130101;
B41J 2/1707 20130101; B41J 2/1714 20130101; B41J 29/13 20130101;
B41J 2/515 20130101; B41J 2202/21 20130101; B41J 2/17556 20130101;
B41J 2002/1742 20130101; B41J 25/34 20130101; B41J 2202/20
20130101; B41J 2/14016 20130101; B41J 2/1752 20130101; B41J 2/16535
20130101; B41J 29/38 20130101; B41J 2002/14419 20130101; B41J
2002/17516 20130101; B41J 2/16585 20130101; B41J 2/04591 20130101;
B41J 2/1623 20130101; B41J 2/17553 20130101; B41J 2/175 20130101;
B41J 2/17513 20130101; B41J 2/17509 20130101; B41J 2202/19
20130101; B41J 2/1642 20130101; B41J 2/17536 20130101; B41J 2/0458
20130101; B41J 2/1637 20130101; B41J 2002/14435 20130101; B41J
2/17506 20130101; B41J 2002/14403 20130101; B41J 2002/14475
20130101; B41J 2/1648 20130101; B41J 2002/14362 20130101; B41J
2/17566 20130101; B41J 2/135 20130101; B41J 2/1628 20130101 |
Class at
Publication: |
347/40 ;
347/85 |
International
Class: |
B41J 2/15 20060101
B41J002/15 |
Claims
1. An inkjet printhead comprising: an integrated circuit having a
plurality of inkjet nozzles formed on one surface and a plurality
of ink delivery channels formed on an opposing surface for
delivering ink to the nozzles; an ink distribution member having a
plurality of conduits formed therethrough, each conduit having an
inlet which receives ink from an ink supply and an outlet for
distributing the received ink to the ink delivery channels of the
integrated circuit; and an adhesive layer adhering the integrated
circuit to the ink distribution member, the adhesive layer having a
plurality of holes aligned with corresponding ones of the outlets
and delivery channels so that ink can be supplied therebetween.
2. A printhead according to claim 1, wherein each outlet of the ink
distribution member distributes ink to at least one section of the
delivery channels for delivering the ink to a number of nozzles of
the integrated circuit predetermined in accordance to the colour of
the ink being distributed
3. A printhead according to claim 2, wherein each outlet supplies
ink to two sections of the delivery channels.
4. A printhead according to claim 1, wherein the inlet and outlet
of each conduit are connected by a tunnel formed within the ink
distribution member, said tunnel providing a path for the ink to
flow from the inlet to the outlet.
5. A printhead according to claim 1, wherein the integrated circuit
is elongate and the delivery channels extend the length of the
integrated circuit.
6. A printhead according to claim 1, wherein the outlets of the
conduits have a width less than or substantially equal to the width
of the delivery channels of the integrated circuits.
7. A printhead according to claim 6, wherein the outlets have a
maximum width less than 80 microns.
8. A printhead according to claim 1, wherein the ink distribution
member is made from a photo-structurable glass ceramic
material.
9. A printhead according to claim 8, wherein the material is
forturan glass.
Description
[0001] The present application is a Continuation of U.S.
application Ser. No. 11/014,762 filed Dec. 20, 2004, which is a
Continuation-In-Part application of U.S. Ser. No. 10/760,254 filed
on Jan. 21, 2004, now issued U.S. Pat. No. 7,448,734.
[0002] In the interests of brevity, the disclosure of the parent
application is incorporated in its entirety into the present
specification by cross reference.
FIELD OF THE INVENTION
[0003] The present invention relates to a printhead assembly for a
pagewidth printhead cartridge, and more particularly to a pagewidth
printhead assembly having a single piece ink distribution member
for distributing the ink to the nozzles of the printhead
assembly.
CO-PENDING APPLICATIONS
[0004] The following applications have been filed by the Applicant
simultaneously with application Ser. No. 11/014,762:
TABLE-US-00001 7,152,972 11/014,731 11/014,764 11/014,763 7,331,663
7,360,861 7,328,973 7,427,121 7,407,262 7,303,252 7,249,822
7,311,382 7,360,860 7,364,257 7,390,075 7,350,896 7,429,096
7,384,135 7,331,660 7,416,287 7,488,052 7,322,684 7,322,685
7,311,381 7,270,405 7,303,268 7,470,007 7,399,072 7,393,076
11/014,750 11/014,749 7,249,833 11/014,769 7,490,927 7,331,661
11/014,733 7,300,140 7,357,492 7,357,493 11/014,766 7,380,902
7,284,816 7,284,845 7,255,430 7,390,080 7,328,984 7,350,913
7,322,671 7,380,910 7,431,424 7,470,006 11/014,732 7,347,534
7,306,320 7,377,635 11/014,727 11/014,730
[0005] The disclosures of these co-pending applications are
incorporated herein by reference.
CROSS REFERENCES TO RELATED APPLICATIONS
[0006] The following patents or patent applications filed by the
applicant or assignee of the present invention are hereby
incorporated by cross-reference.
TABLE-US-00002 7,364,256 7,258,417 7,293,853 7,328,968 7,270,395
7,461,916 7,510,264 7,334,864 7,255,419 7,284,819 7,229,148
7,258,416 7,273,263 7,270,393 6,984,017 7,347,526 7,465,015
7,364,255 7,357,476 11/003,614 7,284,820 7,341,328 7,246,875
7,322,669 6,623,101 6,406,129 6,505,916 6,457,809 6,550,895
6,457,812 7,152,962 6,428,133 7,204,941 7,282,164 7,465,342
7,278,727 7,417,141 7,452,989 7,367,665 7,138,391 7,153,956
7,423,145 7,456,277 10/913,376 7,122,076 7,148,345 7,416,280
7,252,366 7,488,051 7,360,865 10/922,890 7,334,874 7,393,083
7,475,965 10/922,884 10/922,879 10/922,887 7,472,984 10/922,874
7,234,795 7,401,884 7,328,975 7,293,855 7,410,250 7,401,900
10/922,878 7,410,243 7,360,871 10/922,877 6,746,105 7,156,508
7,159,972 7,083,271 7,165,834 7,080,894 7,201,469 7,090,336
7,156,489 7,413,283 7,438,385 7,083,257 7,258,422 7,255,423
7,219,980 10/760,253 7,416,274 7,367,649 7,118,192 10/760,194
7,322,672 7,077,505 7,198,354 7,077,504 10/760,189 7,198,355
7,401,894 7,322,676 7,152,959 7,213,906 7,178,901 7,222,938
7,108,353 7,104,629 7,246,886 7,128,400 7,108,355 6,991,322
7,287,836 7,118,197 10/728,784 7,364,269 7,077,493 6,962,402
10/728,803 7,147,308 10/728,779 7,118,198 7,168,790 7,172,270
7,229,155 6,830,318 7,195,342 7,175,261 7,465,035 7,108,356
7,118,202 7,510,269 7,134,744 7,510,270 7,134,743 7,182,439
7,210,768 7,465,036 7,134,745 7,156,484 7,118,201 7,111,926
7,431,433 09/575,197 7,079,712 6,825,945 7,330,974 6,813,039
6,987,506 7,038,797 6,980,318 6,816,274 7,102,772 7,350,236
6,681,045 6,728,000 7,173,722 7,088,459 09/575,181 7,068,382
7,062,651 6,789,194 6,789,191 6,644,642 6,502,614 6,622,999
6,669,385 6,549,935 6,987,573 6,727,996 6,591,884 6,439,706
6,760,119 7,295,332 7,064,851 6,826,547 6,290,349 6,428,155
6,785,016 6,831,682 6,741,871 6,927,871 6,980,306 6,965,439
6,840,606 7,036,918 6,977,746 6,970,264 7,068,389 7,093,991
7,190,491 7,511,847 10/932,044 10/962,412 7,177,054 7,364,282
10/965,733 10/965,933 10/974,742 10/986,375 6,982,798 6,870,966
6,822,639 6,737,591 7,055,739 7,233,320 6,830,196 6,832,717
6,957,768 7,170,499 7,106,888 7,123,239 10/727,181 10/727,162
7,377,608 7,399,043 7,121,639 7,165,824 7,152,942 10/727,157
7,181,572 7,096,137 7,302,592 7,278,034 7,188,282 10/727,159
10/727,180 10/727,179 10/727,192 10/727,274 10/727,164 10/727,161
10/727,198 10/727,158 10/754,536 10/754,938 10/727,160 10/934,720
7,369,270 6,795,215 7,070,098 7,154,638 6,805,419 6,859,289
6,977,751 6,398,332 6,394,573 6,622,923 6,747,760 6,921,144
10/884,881 7,092,112 7,192,106 7,374,266 7,427,117 7,448,707
7,281,330 10/854,503 7,328,956 10/854,509 7,188,928 7,093,989
7,377,609 10/854,495 10/854,498 10/854,511 7,390,071 10/854,525
10/854,526 10/854,516 7,252,353 10/854,515 7,267,417 10/854,505
10/854,493 7,275,805 7,314,261 10/854,490 7,281,777 7,290,852
7,484,831 10/854,523 10/854,527 10/854,524 10/854,520 10/854,514
10/854,519 10/854,513 10/854,499 10/854,501 7,266,661 7,243,193
10/854,518 10/934,628
BACKGROUND OF THE INVENTION
[0007] Traditionally, most commercially available inkjet printers
have a print engine which forms part of the overall structure and
design of the printer. In this regard, the body of the printer unit
is typically constructed to accommodate the print head and
associated media delivery mechanisms, and these features are
integral with the printer unit.
[0008] This is especially the case with inkjet printers that employ
a printhead that traverses back and forth across the media as the
media is progressed through the printer unit in small iterations.
In such cases the reciprocating printhead is typically mounted to
the body of the printer unit such that it can traverse the width of
the printer unit between a media input roller and a media output
roller, with the media input and output rollers forming part of the
structure of the printer unit. With such a printer unit it may be
possible to remove the printhead for replacement, however the other
parts of the print engine, such as the media transport rollers,
control circuitry and maintenance stations, are typically fixed
within the printer unit and replacement of these parts is not
possible without replacement of the entire printer unit.
[0009] As well as being rather fixed in their design construction,
printer units employing reciprocating type printheads are
considerably slow, particularly when performing print jobs of full
colour and/or photo quality. This is due to the fact that the
printhead must continually traverse the stationary media to deposit
the ink on the surface of the media and it may take a number of
swathes of the printhead to deposit one line of the image.
[0010] Recently, it has been possible to provide a printhead that
extends the entire width of the print media so that the printhead
can remain stationary as the media is transported past the
printhead. Such systems greatly increase the speed at which
printing can occur as the printhead no longer needs to perform a
number of swathes to deposit a line of an image, but rather the
printhead can deposit the ink on the media as it moves past at high
speeds. Such printheads have made it possible to perform full
colour 1600 dpi printing at speeds in the vicinity of 60 pages per
minute, speeds previously unattainable with conventional inkjet
printers.
[0011] Such a pagewidth printhead typically requires high precision
and high speed paper movement and as such the entire print engine
(printhead, paper handling mechanisms and control circuitry etc)
must be configured accordingly to ensure high quality output.
[0012] Accordingly, there is a need to provide a print engine
having a pagewidth printhead that can be readily employed within a
standard body of a printer unit and is constructed in a manner that
ensures that all the necessary parts of the print engine are
configured in a manner that enables consistent, high speed
printing.
SUMMARY OF THE INVENTION
[0013] In a first aspect the present invention provides a pagewidth
printhead assembly for an inkjet printer comprising: [0014] a body
portion for receiving ink from one or more ink sources and having
one or more channels formed therein for distributing the ink
substantially along the length of the printhead assembly; [0015]
one or more integrated circuits extending substantially the length
of the printhead assembly, the or each integrated circuit having a
plurality of nozzles, each of the nozzles being arranged in use to
deliver the ink onto passing print media; and [0016] an ink
distribution member upon which the or each integrated circuit is
fixed and which distributes the ink from the body portion to each
of the integrated circuits; [0017] wherein the ink distribution
member is a unitary element having a plurality of conduits formed
therethrough, each of the conduits having an inlet which receives
ink from one of the channels of the body portion and an outlet
which delivers the ink to a predetermined number of nozzles of the
one or more integrated circuits.
[0018] Optionally the predetermined number of nozzles is selected
due to the colour of the ink carried within the channel of the body
portion
[0019] Optionally the conduits are provided along the length of
each of the channels of the body portion to provide multiple flow
paths for the ink to pass to the integrated circuits.
[0020] Optionally the conduits are equi-spaced along the length of
each of the channels of the body portion.
[0021] Optionally the inlets of the conduits have a width less than
or substantially equal to the width of the channels formed in the
body portion.
[0022] Optionally the inlets have a maximum width of less than 1
mm.
[0023] Optionally the inlet and outlet of each of the conduits are
connected by a tunnel formed within the body of the ink
distribution member, said tunnel providing a path for the ink to
flow from the inlet to the outlet.
[0024] Optionally each integrated circuits has a plurality of
delivery channels formed in a surface thereof for delivering the
ink to nozzles.
[0025] Optionally the delivery channels extend the length of each
integrated circuit.
[0026] Optionally the number of delivery channels formed in the
surface of each integrated circuit is equivalent to the number of
channels provided in the body portion.
[0027] Optionally each delivery channel is in fluid communication
with at least one row of nozzles.
[0028] Optionally the outlet of each conduit delivers ink into one
of the delivery channels for supplying said ink to said
predetermined number of nozzles.
[0029] Optionally the outlets of the conduits have a width less
than or substantially equal to the width of the delivery channels
formed in the surface of the integrated circuits.
[0030] Optionally the outlets have a maximum width less than 80
microns.
[0031] Optionally the delivery channels have a plurality of walls
provided along the length thereof, said walls dividing said
delivery channels into a plurality of sections.
[0032] Optionally each outlet supplies ink to at least one section
of the delivery channels.
[0033] Optionally each outlet supplies ink to two sections of the
delivery channels.
[0034] Optionally the ink distribution member is made from a
photo-structurable glass ceramic material.
[0035] Optionally the material is forturan glass.
[0036] Optionally each integrated circuit is fixed to the ink
distribution member via an adhesive.
[0037] Optionally the adhesive is supplied to each of the
integrated circuits.
[0038] Optionally the adhesive is supplied to the surface of the
ink distribution member.
[0039] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the inkjet printer comprises:
[0040] a media input tray for supplying print media for printing;
[0041] a print engine for printing an image on said print media;
and [0042] a media output tray for collecting the printed media;
[0043] wherein the print engine comprises a removable inkjet
cartridge of a type having a pagewidth printhead and an ink supply
and a cradle having a body adapted to receive the removable inkjet
cartridge and to control the operation of the printhead for
printing;
[0044] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the printhead is arranged for
use in a print engine of the inkjet printer, the print engine
comprising: [0045] a removable inkjet cartridge of a type having
the pagewidth printhead and an ink supply; and [0046] a cradle
having a body adapted to receive the removable inkjet cartridge and
to control the operation of the printhead for printing; [0047]
wherein the cradle is configured to be secured to the inkjet
printer to receive print media from a media input tray and to
deliver printed media to a media output tray.
[0048] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the printhead is arranged for
use with a cartridge unit comprising: [0049] a body portion having
one or more ink storage compartments; and [0050] a pagewidth
printhead assembly mountable to said body and configured to receive
ink from the one or more compartments and to distribute the ink
along the length of the printhead assembly.
[0051] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the printhead is arranged for
use with a cartridge unit comprising: [0052] a body portion having
one or more ink storage compartments; [0053] a pagewidth printhead
assembly mountable to said body portion and configured to receive
ink from the one or more compartments for printing; and [0054] a
capper unit mountable to said body portion so as to extend along
the length of the printhead assembly, the capper unit housing a
capping element which is movable with respect to the capper unit to
contact a surface of the printhead assembly.
[0055] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the printhead is arranged for
use with a cartridge unit comprising: [0056] a body portion housing
one or more ink storage compartments; [0057] a pagewidth printhead
assembly configured to receive ink from the one or more ink storage
compartments and having a plurality of nozzles arranged in use to
deliver the ink onto passing print media; and [0058] an electrical
connector in electrical communication with the nozzles of the
printhead assembly and disposed along the length of the printhead
assembly for mating with a corresponding connectors of the inkjet
printer to control operation of the nozzles.
[0059] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the printhead is arranged for
use with a cartridge unit comprising: [0060] a body portion having
a plurality of ink storage compartments; and [0061] a pagewidth
printhead assembly configured to receive ink from ink storage
compartments and distribute said ink to a plurality of nozzles
arranged in use to deliver the ink onto passing print media; [0062]
wherein the ink storage compartments comprise an absorption
material which stores the ink therein under capillary action for
supply to the nozzles of the printhead assembly.
[0063] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the integrated circuits are
aligned in an abutting arrangement across the length of the ink
distribution member.
[0064] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the body portion has one or
more connectors formed thereon for securing the printhead assembly
to the one or more ink sources to facilitate ink flow
therebetween.
[0065] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein an electrical connector in
electrical communication with the or each integrated circuit
extends along the length of the printhead assembly for mating with
a corresponding electrical connector of the inkjet printer.
[0066] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the ink distribution member
comprises a first layer which directs the ink from the one or more
channels of the body portion for delivery to each integrated
circuit, and a second layer attached to said first layer for
receiving and securing each integrated circuit in a position to
receive the ink from the first layer.
[0067] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the printhead of the assembly
is arranged for use with a capping assembly for capping the
printhead, the capping assembly comprising: [0068] a body
configured to extend the length of the printhead; and [0069] a
capping element housed within said body and movable with respect to
the body to cap at least a portion of said printhead; [0070]
wherein, the body includes a mounting element for removably
mounting said capping assembly to said printhead.
[0071] In a further aspect the present invention provides a
pagewidth printhead assembly, wherein the printhead is arranged for
use with a capping assembly for capping the pagewidth printhead of
the pagewidth printhead assembly, the capping assembly comprising:
[0072] a body configured to extend the length of the printhead; and
[0073] a capping element housed within said body, said capping
element having a rim portion adapted to cap at least a portion of
said printhead; [0074] wherein, the capping element is movable with
respect to said body between a first and a second position, said
first position being where said rim portion extends from said body,
and said second position being where said rim portion is contained
within said body.
[0075] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead being arranged for use
with a capping assembly for capping the pagewidth printhead of the
pagewidth printhead assembly, the capping assembly comprising:
[0076] a body configured to extend the length of the printhead; and
[0077] a capping element housed within said body and movable with
respect to said body between a first and a second position, said
first position being where a portion of the capping element extends
from said body, and said second position being where said capping
element is contained within said body; [0078] wherein, the capping
element is biased into said first position.
[0079] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead being arranged for use
with a capping assembly for capping the pagewidth printhead of the
pagewidth printhead assembly, the capping assembly comprising:
[0080] a body configured to extend the length of the printhead;
[0081] a capping element housed within said body and having a rim
portion adapted to cap at least a portion of the printhead; [0082]
a displacement assembly housed within the body for moving the
capping element between a first position where the rim portion of
the capping element extends from said body, and a second position
where the rim portion of the capping element is contained within
the body; [0083] wherein, the displacement assembly is controlled
by an electromagnet which determines the position.
[0084] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead of the assembly being
arranged for use with a cradle unit comprising: [0085] a body
complementary to a removable inkjet cartridge; and [0086] a
controller for controlling the operation of the printhead to
facilitate printing; [0087] wherein, a plurality of terminals are
located along the length of the body to contact corresponding
terminals located along the length of the removable inkjet
cartridge to enable electrical communication between the controller
and the cartridge.
[0088] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead of the assembly being
arranged for use with a cradle unit comprising: [0089] a body
complementary to a removable inkjet cartridge; [0090] a controller
for controlling the operation of the printhead to facilitate
printing; and [0091] a plurality of terminals in electrical
communication with said controller for transmitting control signals
from said controller to corresponding terminals provided on said
cartridge; [0092] wherein said plurality of terminals are arranged
to pivotally engage with said corresponding terminals provided on
said cartridge when said cartridge is received by said body.
[0093] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead of the assembly being
arranged for use with a cradle unit comprising: [0094] a body
complementary to a removable inkjet cartridge associated with the
printhead and a refillable ink supply; and [0095] a controller for
controlling the operation of the printhead to facilitate printing;
[0096] wherein, said body includes a cover assembly for enclosing
the removable inkjet cartridge within the body, said cover assembly
having at least one port formed therein through which a refill unit
is received for refilling the ink supply of the cartridge.
[0097] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead of the assembly being
arranged for use with a cradle unit comprising: [0098] a body
complementary to a removable inkjet cartridge associated with the
printhead and a refillable ink supply; and [0099] a controller for
controlling the operation of the printhead to facilitate printing;
[0100] wherein, said body is configured to receive a refill unit
for supplying refill ink to the cartridge and includes a refill
actuator for dispensing ink from said refill unit into said
refillable ink supply.
[0101] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead of the assembly being
arranged for use with a cradle unit comprising: [0102] a body
complementary to a removable inkjet cartridge of associated with
the printhead, an ink supply and a capper assembly; and [0103] a
controller for controlling the operation of the printhead to
facilitate printing; [0104] wherein, said body includes an
electromagnet assembly mounted thereto which is controlled by said
controller for operating said capper assembly of the removable
inkjet cartridge.
[0105] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead of the assembly being
arranged for use with a cradle unit having a body complementary to
a removable inkjet cartridge of a type having a pagewidth printhead
and an ink supply and a controller for controlling the operation of
the printhead to facilitate printing; wherein the cradle unit is
arranged for engagement with a cover assembly comprising: [0106] at
least one port formed therein through which a refill unit is
received for refilling the ink supply of the cartridge.
[0107] In a further aspect the present invention provides a
pagewidth printhead assembly, the printhead of the assembly being
arranged for use with a cradle unit having a body complementary to
a removable inkjet cartridge of a type having a pagewidth printhead
and an ink supply and a controller for controlling the operation of
the printhead to facilitate printing;
wherein the cradle unit is arranged for engagement with a cover
assembly comprising a refill actuator for dispensing ink from an
ink refill unit into said refillable ink supply.
[0108] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged in fluid
communication with one or more ink storage compartments within a
cartridge unit, the cartridge unit being arranged for use with an
ink priming system comprising: [0109] a priming inlet provided on
said printhead assembly for receiving a supply of ink for priming
the cartridge unit; and [0110] an ink flow passage providing fluid
connection between said printhead assembly and one of the ink
storage compartments; [0111] wherein the ink supplied to the
priming inlet of the printhead assembly flows from the printhead
assembly to the ink storage compartment via the ink flow passage to
prime both the printhead assembly and the ink storage compartment
with ink simultaneously.
[0112] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged in fluid
communication with one or more ink storage compartments within a
cartridge unit, the cartridge unit being arranged for use with an
ink priming system comprising: [0113] a priming inlet provided on
said printhead assembly for receiving a supply of ink for priming
the cartridge unit; [0114] an ink flow passage providing fluid
connection between said printhead assembly and one of the ink
storage compartments; and [0115] a bypass flow passage providing
additional fluid connection between the ink flow passage and the
ink storage compartment; [0116] wherein the ink supplied to the
priming inlet of the printhead assembly flows from the printhead
assembly to the ink storage compartment via the ink flow passage
and the bypass flow passage to prime both the printhead assembly
and the ink storage compartment with ink simultaneously.
[0117] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged for use
in a cartridge unit adapted for refilling from a printing fluid
refill cartridge that is arranged for use with a printing fluid
dispenser comprising: [0118] a body storing printing fluid having
an outlet through which the printing fluid is dispensed; and [0119]
a selector arranged to select the amount of the printing fluid to
be dispensed from the body.
[0120] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged for use
in a printing unit, which is adapted for refilling with a supply of
printing fluid by a method comprising the steps of: [0121]
removably mounting a dispenser of printing fluid to the printing
unit so as to align an outlet of the dispenser with an inlet of a
printing fluid storage chamber of the printing unit; [0122]
determining an amount of printing fluid needed to substantially
refill the printing fluid storage chamber; and [0123] selectively
dispensing an amount of printing fluid from the dispenser
corresponding to the determined amount.
[0124] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged for use
in a cartridge unit adapted for refilling from a printing fluid
refill cartridge having a dispensing assembly comprising: [0125] a
body for storing printing fluid having an outlet through which the
printing fluid is dispensed; and [0126] a plunger arranged to
selectively change the storage capacity of the body and expel the
printing fluid through said outlet by selective engagement of a
movable retaining member with a series of grooves arranged along a
surface of the plunger, thereby dispensing a selected amount of
printing fluid from the outlet.
[0127] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged for use
in a print engine adapted for refilling from a printing fluid
refill unit, wherein the refilling is controlled by a system
comprising: [0128] an information storage element incorporated in
the refill unit for storing information on the amount of printing
fluid contained in the refill unit; and [0129] an information
reader incorporated in the print engine for reading the information
stored by the storage element when the refill unit is mounted to
the print engine and for controlling the refilling of the print
engine with the printing fluid contained in the refill unit based
on the information read.
[0130] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged for use
in a print engine adapted for refilling from a printing fluid
refill unit comprising an information storage element for storing
information on the amount of printing fluid contained in the refill
unit and for connecting with an information reader incorporated in
the print engine for reading the information stored by the storage
element when the refill unit is mounted to the print engine, [0131]
wherein the information stored by the storage element enables the
reader to control the refilling of the print engine with the
printing fluid contained in the refill unit.
[0132] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged for use
with a printing unit adapted for refilling by a printing fluid
refill cartridge wherein the refilling is controlled by a method
comprising the steps of: [0133] storing information on an amount of
printing fluid contained in the refill cartridge in an information
storage element incorporated therein; [0134] mounting the refill
cartridge to the printing unit; [0135] reading the information on
the amount of printing fluid with an information reader
incorporated in the printing unit; and [0136] controlling the
refilling of the printing unit with printing fluid contained in the
refill cartridge based on the information read.
[0137] In a further aspect the present invention provides a
pagewidth printhead assembly, the assembly being arranged for use
in a printing cartridge having a printing fluid storage device
comprising a porous body having a plurality of individual channels
arranged in an array to store printing fluid and supply the stored
printing fluid to at least one printing fluid ejecting nozzle of a
printhead of a printer unit, [0138] wherein a first end of each of
the channels is in fluid communication with a printing fluid supply
to extract printing fluid from the fluid supply for storage therein
under capillary action and the stored printing fluid is supplied to
the at least one nozzle under capillary action.
[0139] In a further aspect the present invention provides an inkjet
printer unit comprising: [0140] a media input tray for supplying
print media for printing; [0141] a print engine for printing an
image on said print media; and [0142] a media output tray for
collecting the printed media; [0143] wherein the print engine
comprises a removable inkjet cartridge of a type having a pagewidth
printhead and an ink supply and a cradle having a body adapted to
receive the removable inkjet cartridge and to control the operation
of the printhead for printing.
[0144] In a further aspect the present invention provides a print
engine for an inkjet printer comprising: [0145] a removable inkjet
cartridge of a type having a pagewidth printhead and an ink supply;
and [0146] a cradle having a body adapted to receive the removable
inkjet cartridge and to control the operation of the printhead for
printing; [0147] wherein the cradle is configured to be secured to
the inkjet printer to receive print media from a media input tray
and to deliver printed media to a media output tray.
[0148] In a further aspect the present invention provides a
cartridge unit for an inkjet printer comprising: [0149] a body
portion having one or more ink storage compartments; and [0150] a
pagewidth printhead assembly mountable to said body and configured
to receive ink from the one or more compartments and to distribute
the ink along the length of the printhead assembly.
[0151] In a further aspect the present invention provides a
cartridge unit for an inkjet printer comprising: [0152] a body
portion having one or more ink storage compartments; [0153] a
pagewidth printhead assembly mountable to said body portion and
configured to receive ink from the one or more compartments for
printing; and [0154] a capper unit mountable to said body portion
so as to extend along the length of the printhead assembly, the
capper unit housing a capping element which is movable with respect
to the capper unit to contact a surface of the printhead
assembly.
[0155] In a further aspect the present invention provides a
cartridge unit for an inkjet printer comprising: [0156] a body
portion housing one or more ink storage compartments; [0157] a
pagewidth printhead assembly configured to receive ink from the one
or more ink storage compartments and having a plurality of nozzles
arranged in use to deliver the ink onto passing print media; and
[0158] an electrical connector in electrical communication with the
nozzles of the printhead assembly and disposed along the length of
the printhead assembly for mating with a corresponding connectors
of the inkjet printer to control operation of the nozzles.
[0159] In a further aspect the present invention provides cartridge
unit for an inkjet printer comprising: [0160] a body portion having
a plurality of ink storage compartments; and [0161] a pagewidth
printhead assembly configured to receive ink from ink storage
compartments and distribute said ink to a plurality of nozzles
arranged in use to deliver the ink onto passing print media; [0162]
wherein the ink storage compartments comprise an absorption
material which stores the ink therein under capillary action for
supply to the nozzles of the printhead assembly.
[0163] In a further aspect the present invention provided a
pagewidth printhead assembly for an inkjet printer comprising:
[0164] a body portion for receiving ink from one or more ink
sources and distributing the ink along the length of the printhead
assembly; [0165] a plurality of integrated circuits extending the
length of the printhead assembly, each integrated circuit having a
plurality of nozzles formed in rows thereon, each of the nozzles
being arranged in use to deliver the ink onto passing print media;
and [0166] an ink distribution member upon which the integrated
circuits are fixed and which distributes the ink from the body
portion to the nozzles of the integrated circuits; [0167] wherein
the integrated circuits are aligned in an abutting arrangement
across the length of the ink distribution member.
[0168] In an further aspect the present invention provides a
pagewidth printhead assembly for an inkjet printer comprising:
[0169] a body portion for receiving ink from one or more ink
sources and distributing the ink along the length of the printhead
assembly; [0170] one or more integrated circuits extending
substantially the length of the printhead assembly, the or each
integrated circuit having a plurality of nozzles formed thereon,
each of the nozzles being arranged in use to deliver the ink onto
passing print media; and [0171] an ink distribution member upon
which the or each integrated circuit are fixed and which
distributes the ink from the body portion to the nozzles of the or
each integrated circuit; [0172] wherein the body portion has one or
more connectors formed thereon for securing the printhead assembly
to the one or more ink sources to facilitate ink flow
therebetween.
[0173] In a further aspect the present invention provides a
pagewidth printhead assembly for an inkjet printer comprising:
[0174] a body portion for receiving ink from one or more ink
sources and distributing the ink along the length of the printhead
assembly; [0175] one or more integrated circuits extending
substantially the length of the printhead assembly, the or each
integrated circuit having a plurality of nozzles formed thereon,
each of the nozzles being arranged in use to deliver the ink onto
passing print media; and [0176] an ink distribution member upon
which the or each integrated circuit is fixed and which distributes
the ink from the body portion to the nozzles of the or each
integrated circuit; [0177] wherein an electrical connector in
electrical communication with the or each integrated circuit
extends along the length of the printhead assembly for mating with
a corresponding electrical connector of the inkjet printer.
[0178] In a further aspect the present invention provides a
pagewidth printhead assembly for an inkjet printer comprising:
[0179] a body portion for receiving ink from one or more ink
sources and having one or more channels formed therein for
distributing the ink substantially along the length of the
printhead assembly; [0180] one or more integrated circuits
extending substantially the length of the printhead assembly, the
or each integrated circuit having a plurality of nozzles, each of
the nozzles being arranged in use to deliver the ink onto passing
print media; and [0181] an ink distribution member upon which the
or each integrated circuit is fixed and which distributes the ink
from the body portion to each of the integrated circuits; [0182]
wherein the ink distribution member is a unitary element having a
plurality of conduits formed therethrough, each of the conduits
having an inlet which receives ink from one of the channels of the
body portion and an outlet which delivers the ink to a
predetermined number of nozzles of the one or more integrated
circuits.
[0183] In a further aspect the present invention provides a
pagewidth printhead assembly for an inkjet printer comprising:
[0184] a body portion for receiving ink from one or more ink
sources and having one or more channels formed therein for
distributing the ink substantially along the length of the
printhead assembly; [0185] one or more integrated circuits
extending substantially the length of the printhead assembly, each
integrated circuit having a plurality of nozzles, each of the
nozzles being arranged in use to deliver the ink onto passing print
media; and [0186] an ink distribution member upon which each
integrated circuit is fixed and which distributes the ink from the
body portion to each of the integrated circuits; [0187] wherein the
ink distribution member comprises a first layer which directs the
ink from the one or more channels of the body portion for delivery
to each integrated circuit, and a second layer attached to said
first layer for receiving and securing each integrated circuit in a
position to receive the ink from the first layer.
[0188] In a further aspect the present invention provides a capping
assembly for capping a pagewidth printhead of an inkjet printer
comprising: [0189] a body configured to extend the length of the
printhead; and [0190] a capping element housed within said body and
movable with respect to the body to cap at least a portion of said
printhead; [0191] wherein, the body includes a mounting element for
removably mounting said capping assembly to said printhead.
[0192] In a further aspect the present invention provides a capping
assembly for capping a pagewidth printhead of an inkjet printer
comprising: [0193] a body configured to extend the length of the
printhead; and [0194] a capping element housed within said body,
said capping element having a rim portion adapted to cap at least a
portion of said printhead; [0195] wherein, the capping element is
movable with respect to said body between a first and a second
position, said first position being where said rim portion extends
from said body, and said second position being where said rim
portion is contained within said body.
[0196] In a further aspect the present invention provides a capping
assembly for capping a pagewidth printhead of an inkjet printer
comprising: [0197] a body configured to extend the length of the
printhead; and [0198] a capping element housed within said body and
movable with respect to said body between a first and a second
position, said first position being where a portion of the capping
element extends from said body, and said second position being
where said capping element is contained within said body; [0199]
wherein, the capping element is biased into said first
position.
[0200] In a further aspect the present invention provides a capping
assembly for capping a pagewidth printhead of an inkjet printer
comprising: [0201] a body configured to extend the length of the
printhead; [0202] a capping element housed within said body and
having a rim portion adapted to cap at least a portion of the
printhead; [0203] a displacement assembly housed within the body
for moving the capping element between a first position where the
rim portion of the capping element extends from said body, and a
second position where the rim portion of the capping element is
contained within the body; [0204] wherein, the displacement
assembly is controlled by an electromagnet which determines the
position.
[0205] In a further aspect the present invention provides a cradle
unit for an inkjet printer comprising: [0206] a body complementary
to a removable inkjet cartridge of a type having a pagewidth
printhead and an ink supply; and [0207] a controller for
controlling the operation of the printhead to facilitate printing;
[0208] wherein, a plurality of terminals are located along the
length of the body to contact corresponding terminals located along
the length of the removable inkjet cartridge to enable electrical
communication between the controller and the cartridge.
[0209] In a further aspect the present invention provides a cradle
unit for an inkjet printer comprising: [0210] a body complementary
to a removable inkjet cartridge of a type having a pagewidth
printhead and an ink supply; [0211] a controller for controlling
the operation of the printhead to facilitate printing; and [0212] a
plurality of terminals in electrical communication with said
controller for transmitting control signals from said controller to
corresponding terminals provided on said cartridge; [0213] wherein
said plurality of terminals are arranged to pivotally engage with
said corresponding terminals provided on said cartridge when said
cartridge is received by said body.
[0214] In a further aspect the present invention provides a cradle
unit for an inkjet printer comprising: [0215] a body complementary
to a removable inkjet cartridge of a type having a pagewidth
printhead and a refillable ink supply; and [0216] a controller for
controlling the operation of the printhead to facilitate printing;
[0217] wherein, said body includes a cover assembly for enclosing
the removable inkjet cartridge within the body, said cover assembly
having at least one port formed therein through which a refill unit
is received for refilling the ink supply of the cartridge.
[0218] In a further aspect the present invention provides a cradle
unit for an inkjet printer comprising: [0219] a body complementary
to a removable inkjet cartridge of a type having a pagewidth
printhead and a refillable ink supply; and [0220] a controller for
controlling the operation of the printhead to facilitate printing;
[0221] wherein, said body is configured to receive a refill unit
for supplying refill ink to the cartridge and includes a refill
actuator for dispensing ink from said refill unit into said
refillable ink supply.
[0222] In a further aspect the present invention provides a cradle
unit for an inkjet printer comprising: [0223] a body complementary
to a removable inkjet cartridge of a type having a pagewidth
printhead, an ink supply and a capper assembly; and [0224] a
controller for controlling the operation of the printhead to
facilitate printing; [0225] wherein, said body includes an
electromagnet assembly mounted thereto which is controlled by said
controller for operating said capper assembly of the removable
inkjet cartridge.
[0226] In a further aspect the present invention provides a cover
assembly for a cradle unit of an inkjet printer having a body
complementary to a removable inkjet cartridge of a type having a
pagewidth printhead and an ink supply and a controller for
controlling the operation of the printhead to facilitate printing;
the cover assembly comprising: [0227] at least one port formed
therein through which a refill unit is received for refilling the
ink supply of the cartridge.
[0228] In a further aspect the present invention provides a cover
assembly for a cradle unit of an inkjet printer having a body
complementary to a removable inkjet cartridge of a type having a
pagewidth printhead and an ink supply and a controller for
controlling the operation of the printhead to facilitate printing;
the cover assembly comprising: [0229] a refill actuator for
dispensing ink from an ink refill unit into said refillable ink
supply.
[0230] In a further aspect the present invention provides an ink
priming system for a cartridge unit of the type having a pagewidth
printhead assembly in fluid communication with one or more ink
storage compartments, the system comprising: [0231] a priming inlet
provided on said printhead assembly for receiving a supply of ink
for priming the cartridge unit; and [0232] an ink flow passage
providing fluid connection between said printhead assembly and one
of the ink storage compartments; [0233] wherein the ink supplied to
the priming inlet of the printhead assembly flows from the
printhead assembly to the ink storage compartment via the ink flow
passage to prime both the printhead assembly and the ink storage
compartment with ink simultaneously.
[0234] In a further aspect the present invention provides an ink
priming system for a cartridge unit of the type having a pagewidth
printhead assembly in fluid communication with one or more ink
storage compartments, the system comprising: [0235] a priming inlet
provided on said printhead assembly for receiving a supply of ink
for priming the cartridge unit; [0236] an ink flow passage
providing fluid connection between said printhead assembly and one
of the ink storage compartments; and [0237] a bypass flow passage
providing additional fluid connection between the ink flow passage
and the ink storage compartment; [0238] wherein the ink supplied to
the priming inlet of the printhead assembly flows from the
printhead assembly to the ink storage compartment via the ink flow
passage and the bypass flow passage to prime both the printhead
assembly and the ink storage compartment with ink
simultaneously.
[0239] In a further aspect the present invention provides a
printing fluid dispenser for a printing fluid refill cartridge
comprising: [0240] a body storing printing fluid having an outlet
through which the printing fluid is dispensed; and [0241] a
selector arranged to select the amount of the printing fluid to be
dispensed from the body.
[0242] In a further aspect the present invention provides a method
of refilling a supply of printing fluid in a printing unit,
comprising the steps of: [0243] removably mounting a dispenser of
printing fluid to the printing unit so as to align an outlet of the
dispenser with an inlet of a printing fluid storage chamber of the
printing unit; [0244] determining an amount of printing fluid
needed to substantially refill the printing fluid storage chamber;
and [0245] selectively dispensing an amount of printing fluid from
the dispenser corresponding to the determined amount.
[0246] In a further aspect the present invention provides a
dispensing assembly for a printing fluid refill cartridge, the
dispensing assembly comprising: [0247] a body for storing printing
fluid having an outlet through which the printing fluid is
dispensed; and [0248] a plunger arranged to selectively change the
storage capacity of the body and expel the printing fluid through
said outlet by selective engagement of a movable retaining member
with a series of grooves arranged along a surface of the plunger,
thereby dispensing a selected amount of printing fluid from the
outlet.
[0249] In a further aspect the present invention provides a system
for controlling refilling of a print engine by a printing fluid
refill unit, comprising: [0250] an information storage element
incorporated in the refill unit for storing information on the
amount of printing fluid contained in the refill unit; and [0251]
an information reader incorporated in the print engine for reading
the information stored by the storage element when the refill unit
is mounted to the print engine and for controlling the refilling of
the print engine with the printing fluid contained in the refill
unit based on the information read.
[0252] In a further aspect the present invention provides a
printing fluid refill unit for a print engine, comprising an
information storage element for storing information on the amount
of printing fluid contained in the refill unit and for connecting
with an information reader incorporated in the print engine for
reading the information stored by the storage element when the
refill unit is mounted to the print engine, [0253] wherein the
information stored by the storage element enables the reader to
control the refilling of the print engine with the printing fluid
contained in the refill unit.
[0254] In a further aspect the present invention provides a method
of controlling refilling of a printing unit by a printing fluid
refill cartridge, comprising the steps of: [0255] storing
information on an amount of printing fluid contained in the refill
cartridge in an information storage element incorporated therein;
[0256] mounting the refill cartridge to the printing unit; [0257]
reading the information on the amount of printing fluid with an
information reader incorporated in the printing unit; and [0258]
controlling the refilling of the printing unit with printing fluid
contained in the refill cartridge based on the information
read.
[0259] In a further aspect the present invention provides a
printing fluid storage device comprising a porous body having a
plurality of individual channels arranged in an array to store
printing fluid and supply the stored printing fluid to at least one
printing fluid ejecting nozzle of a printhead of a printer unit,
[0260] wherein a first end of each of the channels is in fluid
communication with a printing fluid supply to extract printing
fluid from the fluid supply for storage therein under capillary
action and the stored printing fluid is supplied to the at least
one nozzle under capillary action.
BRIEF DESCRIPTION OF THE DRAWINGS
[0261] In the drawings:
[0262] FIG. 1 shows a front perspective view of a printer unit
employing a print engine according to an embodiment of the present
invention;
[0263] FIG. 2 shows the printer unit of FIG. 1 with the lid open
exposing the print engine;
[0264] FIG. 3 shows a schematic of document data flow in a printing
system according to one embodiment of the present invention;
[0265] FIG. 4 shows a more detailed schematic showing an
architecture used in the printing system of FIG. 3;
[0266] FIG. 5 shows a block diagram of an embodiment of the control
electronics as used in the printing system of FIG. 3;
[0267] FIG. 6 shows an exploded perspective view of a print engine
according to an embodiment of the present invention;
[0268] FIG. 7 shows the print engine of FIG. 6 with cartridge unit
inserted in the cradle unit;
[0269] FIG. 8 shows the cradle unit of FIG. 7 with the cover
assembly in the closed position;
[0270] FIG. 9 shows a front perspective view of the cartridge unit
of FIG. 7;
[0271] FIG. 10 shows a front perspective view of the underside of
the cartridge unit of FIG. 9;
[0272] FIG. 11 shows an exploded perspective view of the cartridge
unit of FIG. 7;
[0273] FIG. 12 shows an alternative exploded view of the cartridge
unit of FIG. 7;
[0274] FIG. 13 shows a front perspective view of the main body of
the cartridge unit of FIG. 7 with the lid assembly removed;
[0275] FIG. 14 shows an exploded front perspective view of the main
body of FIG. 13;
[0276] FIG. 15 shows a sectional side view of the main body of FIG.
13;
[0277] FIG. 16 shows an example of an ink storage arrangement for
use in the cartridge unit of FIG. 9 according to one
embodiment;
[0278] FIG. 17 shows a cross-sectional view of an ink storage
compartment employing the ink storage arrangement of FIG. 16
[0279] FIG. 18 shows a front perspective view of a printhead
assembly suitable for use with the cartridge unit of FIG. 9;
[0280] FIG. 19 shows a front perspective view of the underside of
the printhead assembly of FIG. 18;
[0281] FIG. 20 shows an exploded view of the printhead assembly of
FIG. 18;
[0282] FIG. 21 shows a cross-sectional end view of the printhead
assembly of FIG. 18;
[0283] FIG. 22 shows a simplified schematic depiction of linked
integrated circuits according to one embodiment of the present
invention;
[0284] FIG. 23 shows a simplified schematic depiction of two linked
integrated circuits employing a right angled join;
[0285] FIGS. 24A and 24B show a schematic depiction of two linked
integrated circuits employing an angled join;
[0286] FIG. 25 shows a simplified schematic depiction of two linked
integrated circuits employing a vertical offset join;
[0287] FIG. 26 shows a simplified schematic depiction of two linked
integrated circuits employing a sloped placement join;
[0288] FIGS. 27A and 27B show a simplified schematic drawing of two
linked integrated circuits employing a dropped triangle nozzle
join;
[0289] FIG. 28A shows a magnified perspective view of an integrated
circuit as shown in FIGS. 27A and 27B employing a dropped triangle
nozzle arrangement;
[0290] FIG. 28B shows a magnified perspective view of the join
between two integrated circuits employing the nozzle arrangement of
FIG. 28A;
[0291] FIG. 28C shows an underside view of the integrated circuit
of FIG. 28A;
[0292] FIG. 29 shows an exploded perspective view of an alternative
printhead assembly according to another embodiment of the present
invention;
[0293] FIG. 30 shows a partly assembled perspective view of the
printhead assembly of FIG. 29;
[0294] FIG. 31 shows a plurality of holes being laser drilled into
the adhesive layer of the printhead assembly of FIG. 29;
[0295] FIG. 32 shows a plurality of integrated circuits being
arranged along the surface of the adhesive layer of FIG. 31;
[0296] FIGS. 33A-33C show various views of a portion of an ink
distribution member according to a further embodiment of the
present invention;
[0297] FIG. 34A shows a transparent top view of a printhead
assembly employing the ink distribution member of FIGS. 33A-33C
showing in particular, the ink passages for supplying ink to the
integrated circuits;
[0298] FIG. 34B shows an enlarged view of FIG. 34A;
[0299] FIG. 35 shows a schematic view of a priming arrangement for
priming an ink storage compartment of the present invention;
[0300] FIG. 36 shows a schematic view of an alternative priming
arrangement for priming an ink storage compartment of the present
invention;
[0301] FIG. 37 shows a schematic view of the priming arrangement of
FIG. 36 with the bypass valve in the closed position;
[0302] FIG. 38 shows a schematic view of yet another alternative
priming arrangement for priming an ink storage compartment of the
present invention;
[0303] FIG. 39 shows a schematic view of the alternative priming
arrangement of FIG. 38 with the bypass valve in a closed
position.
[0304] FIG. 40 shows yet another alternative arrangement for
priming the ink storage compartment of the present invention,
employing a needle which passes through the side wall of the
compartment;
[0305] FIG. 41 shows a vertical sectional view of a single nozzle
for ejecting ink, for use with the invention, in a quiescent
state;
[0306] FIG. 42 shows a vertical sectional view of the nozzle of
FIG. 41 during an initial actuation phase;
[0307] FIG. 43 shows a vertical sectional view of the nozzle of
FIG. 42 later in the actuation phase;
[0308] FIG. 44 shows a perspective partial vertical sectional view
of the nozzle of FIG. 41, at the actuation state shown in FIG.
43;
[0309] FIG. 45 shows a perspective vertical section of the nozzle
of FIG. 41, with ink omitted;
[0310] FIG. 46 shows a vertical sectional view of the of the nozzle
of FIG. 45;
[0311] FIG. 47 shows a perspective partial vertical sectional view
of the nozzle of FIG. 41, at the actuation state shown in FIG.
42;
[0312] FIG. 48 shows a plan view of the nozzle of FIG. 41;
[0313] FIG. 49 shows a plan view of the nozzle of FIG. 41 with the
lever arm and movable nozzle removed for clarity;
[0314] FIG. 50 shows a perspective vertical sectional view of a
part of a printhead chip incorporating a plurality of the nozzle
arrangements of the type shown in FIG. 41;
[0315] FIG. 51 shows a schematic cross-sectional view through an
ink chamber of a single nozzle for injecting ink of a bubble
forming heater element actuator type.
[0316] FIGS. 52(A) to 52(C) show the basic operational principles
of a thermal bend actuator;
[0317] FIG. 53 shows a three dimensional view of a single inkjet
nozzle arrangement constructed in accordance with FIG. 22;
[0318] FIG. 54 shows an array of the nozzle arrangements shown in
FIG. 53;
[0319] FIG. 55 shows a schematic showing CMOS drive and control
blocks for use with the printer of the present invention;
[0320] FIG. 56 shows a schematic showing the relationship between
nozzle columns and dot shift registers in the CMOS blocks of FIG.
55;
[0321] FIG. 57 shows a more detailed schematic showing a unit cell
and its relationship to the nozzle columns and dot shift registers
of FIG. 56;
[0322] FIG. 58 shows a circuit diagram showing logic for a single
printer nozzle in the printer of the present invention;
[0323] FIG. 59 shows a front perspective view of a lid assembly of
a cartridge unit according to an embodiment of the present
invention;
[0324] FIG. 60 shows a front perspective view of the underside of
the lid assembly of FIG. 59;
[0325] FIG. 61 shows an exploded front perspective view of the lid
assembly of FIG. 59;
[0326] FIG. 62 shows a front perspective view of a capper assembly
of a cartridge unit according to an embodiment of the present
invention;
[0327] FIG. 63 shows an exploded front perspective view of the
capper assembly of FIG. 62;
[0328] FIG. 64 shows an exploded front perspective view of the
underside of the capper assembly of FIG. 62;
[0329] FIG. 65 shows a sectional end view of the capper assembly of
FIG. 62;
[0330] FIG. 66 shows a sectional perspective view of the capper
assembly operationally mounted to the cartridge unit of the present
invention in a capped state;
[0331] FIG. 67 shows a sectional perspective view of the capper
assembly operationally mounted to the cartridge unit of the present
invention in an uncapped state;
[0332] FIGS. 68A-68D show various perspective views of the frame
structure of the cradle unit according to an embodiment of the
present invention;
[0333] FIG. 69 shows a perspective front view of a cartridge unit
support member of the cradle unit according to an embodiment of the
present invention;
[0334] FIG. 70 shows a perspective side view of the frame structure
of FIGS. 68a-68d with the cartridge unit support member of FIG. 69
attached thereto;
[0335] FIGS. 71A-71B show various views of the idle roller assembly
of the cradle unit according to one embodiment of the present
invention;
[0336] FIG. 72 shows a sectional side view of the idle roller
assembly of FIGS. 71A-71B mounted to the cartridge support member
of FIG. 69;
[0337] FIGS. 73A and 73B show front and back perspective views of
the PCB assembly of the present invention having the control
circuitry mounted thereto for controlling the print engine of the
present invention;
[0338] FIGS. 74A-74C show various views of the PCB assembly of
FIGS. 73a and 73b mounted between arm supports;
[0339] FIGS. 75A and 75B show a support bar assembly for the PCB
assembly of FIGS. 73A and 73B in accordance with one embodiment of
the present invention;
[0340] FIG. 76 shows a perspective view of the support bar assembly
of FIGS. 75A and 75B assembled to the PCB assembly of FIGS.
74A-74C;
[0341] FIGS. 77A and 77B shows perspective views of the assembly of
FIG. 76 attached to the cradle unit of the present invention;
[0342] FIG. 78A-78C show various views of the cover assembly of the
cradle unit according to an embodiment of the present
invention;
[0343] FIG. 79 shows a perspective view of the cover assembly as
attached to the cradle unit;
[0344] FIG. 80 shows the print engine of the present invention with
the cover assembly in an open position;
[0345] FIG. 81 shows the print engine of the present invention with
the cover assembly in a closed position;
[0346] FIG. 82 shows a front perspective view of the push rod
assembly in isolation from the cover assembly;
[0347] FIG. 83 shows a perspective view of the foot portion of the
push rod assembly of FIG. 82;
[0348] FIG. 84 shows an ink refill unit according to one embodiment
of the present invention;
[0349] FIG. 85 shows the ink refill unit of FIG. 84 in relation to
the print engine of the present invention;
[0350] FIG. 86 shows the ink refill unit positioned for refilling
ink within the print engine as shown in FIG. 85;
[0351] FIG. 87 shows the cartridge unit as removed from the cradle
unit of FIGS. 85 and 86;
[0352] FIG. 88 shows an underside view of the ink refill unit of
FIG. 84;
[0353] FIG. 89 illustrates the ink refill unit of FIG. 84 with its
lid assembly removed;
[0354] FIG. 90 shows an exploded view of the various components of
the ink refill unit of FIG. 84;
[0355] FIG. 91 illustrates a syringe assembly isolated from the ink
refill unit as shown in FIGS. 89 and 90;
[0356] FIG. 92 shows an end perspective view of the syringe
assembly as shown in FIG. 91;
[0357] FIG. 93 illustrates a base assembly isolated from the other
components of the ink refill unit as shown in FIGS. 89 and 90;
[0358] FIGS. 94A-94C show an ink distribution system provided by
the ink refill unit positioned on the print engine as shown in FIG.
85;
[0359] FIG. 95 shows the ink refill unit with its lid assembly
removed in accordance with an alternative embodiment of a syringe
assembly;
[0360] FIG. 96 shows an exploded view of the various components of
the ink refill unit as shown in FIG. 95;
[0361] FIG. 97 shows a syringe assembly isolated from the ink
refill unit as shown in FIG. 95;
[0362] FIG. 98 shows an end sectional view of the syringe assembly
as shown in FIG. 95;
[0363] FIG. 99 shows a base assembly isolated from the other
components of the ink refill unit as shown in FIGS. 95 and 96;
[0364] FIG. 100 shows yet another embodiment of an ink refill unit
suitable for use with the present invention;
[0365] FIG. 101 shows an opposite perspective view of the ink
refill unit of FIG. 100;
[0366] FIG. 102 shows an underside view of the ink refill unit of
FIG. 100;
[0367] FIG. 103 shows the ink refill unit of FIG. 100 with its end
cap removed;
[0368] FIG. 104 shows an exploded view of the various components of
the ink refill unit of FIG. 100;
[0369] FIG. 105 shows the working relationship between the internal
components of the ink refill unit as shown in FIGS. 100 and 104;
and
[0370] FIG. 106 shows a side sectional view of the ink refill unit
of FIG. 100.
DETAILED DESCRIPTION OF EMBODIMENTS
[0371] As discussed previously, the present invention resides in a
print engine 1 that can be readily incorporated into a body of a
printer unit 2 to perform the printing functions of the printer
unit.
[0372] As shown in FIGS. 1 and 2, the printer unit 2, which
incorporates the print engine 1, may be in any form but typically
has a media supply region 3 for supporting and supplying media 8 to
be printed by the print engine, and a media output or collection
region 4 for collecting the printed sheets of media. The printer
unit 2 may also have a user interface 5 for enabling a user to
control the operation of the printer unit, and this user interface
5 may be in the form of an LCD touch screen as shown.
[0373] The printer unit 2 typically has an internal cavity 6 for
receiving the print engine 1, and access to the internal cavity may
be provided by a lid 7 which is hingedly attached to the body of
the printer unit 2.
[0374] The print engine 1 is configured to be positioned and
secured within the printer unit 2 such that media 8 located in
media supply region 3 can be fed to the print engine 1 for printing
and delivered to the collection region 4 for collection following
printing. In this regard, the print engine 1 includes media
transport means which take the sheets of media 8 from the media
supply region 3 and deliver the media past the printhead assembly,
where it is printed, into the media output tray 4. A picker
mechanism 9 is provided with the printer unit 2 to assist in
feeding individual streets of media 8 from the media supply 3 to
the print engine 1.
[0375] As shown schematically in FIG. 3, in use, the printer unit 2
is arranged to print documents received from an external source,
such as a computer system 702, onto a print media, such as a sheet
of paper. In this regard, the printer unit 100 includes means which
allow electrical connection between the printer unit 2 and the
computer system 702 to receive data which has been pre-processed by
the computer system 702. In one form, the external computer system
702 is programmed to perform various steps involved in printing a
document, including receiving the document (step 703), buffering it
(step 704) and rasterizing it (step 706), and then compressing it
(step 708) for transmission to the printer unit 2.
[0376] The printer unit 2 according to one embodiment of the
present invention, receives the document from the external computer
system 702 in the form of a compressed, multi-layer page image,
wherein control electronics provided within the print engine 1
buffers the image (step 710), and then expands the image (step 712)
for further processing. The expanded contone layer is dithered
(step 714) and then the black layer from the expansion step is
composited over the dithered contone layer (step 716). Coded data
may also be rendered (step 718) to form an additional layer, to be
printed (if desired) using an infrared ink that is substantially
invisible to the human eye. The black, dithered contone and
infrared layers are combined (step 720) to form a page that is
supplied to a printhead for printing (step 722).
[0377] In this particular arrangement, the data associated with the
document to be printed is divided into a high-resolution bi-level
mask layer for text and line art and a medium-resolution contone
color image layer for images or background colors. Optionally,
colored text can be supported by the addition of a
medium-to-high-resolution contone texture layer for texturing text
and line art with color data taken from an image or from flat
colors. The printing architecture generalises these contone layers
by representing them in abstract "image" and "texture" layers which
can refer to either image data or flat color data. This division of
data into layers based on content follows the base mode Mixed
Raster Content (MRC) mode as would be understood by a person
skilled in the art. Like the MRC base mode, the printing
architecture makes compromises in some cases when data to be
printed overlap. In particular, in one form all overlaps are
reduced to a 3-layer representation in a process (collision
resolution) embodying the compromises explicitly.
[0378] As mentioned previously, data is delivered to the printer
unit 2 in the form of a compressed, multi-layer page image with the
pre-processing of the image performed by a mainly software-based
computer system 702. In turn, the print engine 1 processes this
data using a mainly hardware-based system as is shown in more
detail in FIG. 4.
[0379] Upon receiving the data, a distributor 730 converts the data
from a proprietary representation into a hardware-specific
representation and ensures that the data is sent to the correct
hardware device whilst observing any constraints or requirements on
data transmission to these devices. The distributor 730 distributes
the converted data to an appropriate one of a plurality of
pipelines 732. The pipelines are identical to each other, and in
essence provide decompression, scaling and dot compositing
functions to generate a set of printable dot outputs.
[0380] Each pipeline 732 includes a buffer 734 for receiving the
data. A contone decompressor 736 decompresses the color contone
planes, and a mask decompressor decompresses the monotone (text)
layer. Contone and mask scalers 740 and 742 scale the decompressed
contone and mask planes respectively, to take into account the size
of the medium onto which the page is to be printed.
[0381] The scaled contone planes are then dithered by ditherer 744.
In one form, a stochastic dispersed-dot dither is used. Unlike a
clustered-dot (or amplitude-modulated) dither, a dispersed-dot (or
frequency-modulated) dither reproduces high spatial frequencies
(i.e. image detail) almost to the limits of the dot resolution,
while simultaneously reproducing lower spatial frequencies to their
full color depth, when spatially integrated by the eye. A
stochastic dither matrix is carefully designed to be relatively
free of objectionable low-frequency patterns when tiled across the
image. As such, its size typically exceeds the minimum size
required to support a particular number of intensity levels (e.g.
16.times.16.times.8 bits for 257 intensity levels).
[0382] The dithered planes are then composited in a dot compositor
746 on a dot-by-dot basis to provide dot data suitable for
printing. This data is forwarded to data distribution and drive
electronics 748, which in turn distributes the data to the correct
nozzle actuators 750, which in turn cause ink to be ejected from
the correct nozzles 752 at the correct time in a manner which will
be described in more detail later in the description.
[0383] As will be appreciated, the components employed within the
print engine 1 to process the image for printing depend greatly
upon the manner in which data is presented. In this regard it may
be possible for the print engine 1 to employ additional software
and/or hardware components to perform more processing within the
printer unit 2 thus reducing the reliance upon the computer system
702. Alternatively, the print engine 1 may employ fewer software
and/or hardware components to perform less processing thus relying
upon the computer system 702 to process the image to a higher
degree before transmitting the data to the printer unit 2.
[0384] In all situations, the components necessary to perform the
above mentioned tasks are provided within the control electronics
of the print engine 1, and FIG. 5 provides a block representation
of an embodiment of the electronics.
[0385] In this arrangement, the hardware pipelines 732 are embodied
in a Small Office Home Office Printer Engine Chip (SoPEC). As
shown, a SoPEC device consists of 3 distinct subsystems: a Central
Processing Unit (CPU) subsystem 771, a Dynamic Random Access Memory
(DRAM) subsystem 772 and a Print Engine Pipeline (PEP) subsystem
773.
[0386] The CPU subsystem 771 includes a CPU 775 that controls and
configures all aspects of the other subsystems. It provides general
support for interfacing and synchronizing all elements of the print
engine 1. It also controls the low-speed communication to QA chips
(which are described below). The CPU subsystem 771 also contains
various peripherals to aid the CPU, such as General Purpose Input
Output (GPIO, which includes motor control), an Interrupt
Controller Unit (ICU), LSS Master and general timers. The Serial
Communications Block (SCB) on the CPU subsystem provides a full
speed USB1.1 interface to the host as well as an Inter SoPEC
Interface (ISI) to other SoPEC devices (not shown).
[0387] The DRAM subsystem 772 accepts requests from the CPU, Serial
Communications Block (SCB) and blocks within the PEP subsystem. The
DRAM subsystem 772, and in particular the DRAM Interface Unit
(DIU), arbitrates the various requests and determines which request
should win access to the DRAM. The DIU arbitrates based on
configured parameters, to allow sufficient access to DRAM for all
requesters. The DIU also hides the implementation specifics of the
DRAM such as page size, number of banks and refresh rates.
[0388] The Print Engine Pipeline (PEP) subsystem 773 accepts
compressed pages from DRAM and renders them to bi-level dots for a
given print line destined for a printhead interface (PHI) that
communicates directly with the printhead. The first stage of the
page expansion pipeline is the Contone Decoder Unit (CDU), Lossless
Bi-level Decoder (LBD) and, where required, Tag Encoder (TE). The
CDU expands the JPEG-compressed contone (typically CMYK) layers,
the LBD expands the compressed bi-level layer (typically K), and
the TE encodes any Netpage tags for later rendering (typically in
IR or K ink), in the event that the printer unit 2 has Netpage
capabilities. The output from the first stage is a set of buffers:
the Contone FIFO unit (CFU), the Spot FIFO Unit (SFU), and the Tag
FIFO Unit (TFU). The CFU and SFU buffers are implemented in
DRAM.
[0389] The second stage is the Halftone Compositor Unit (HCU),
which dithers the contone layer and composites position tags and
the bi-level spot layer over the resulting bi-level dithered
layer.
[0390] A number of compositing options can be implemented,
depending upon the printhead with which the SoPEC device is used.
Up to 6 channels of bi-level data are produced from this stage,
although not all channels may be present on the printhead. For
example, the printhead may be CMY only, with K pushed into the CMY
channels and IR ignored. Alternatively, any encoded tags may be
printed in K if IR ink is not available (or for testing
purposes).
[0391] In the third stage, a Dead Nozzle Compensator (DNC)
compensates for dead nozzles in the printhead by color redundancy
and error diffusing of dead nozzle data into surrounding dots.
[0392] The resultant bi-level 5 channel dot-data (typically CMYK,
Infrared) is buffered and written to a set of line buffers stored
in DRAM via a Dotline Writer Unit (DWU).
[0393] Finally, the dot-data is loaded back from DRAM, and passed
to the printhead interface via a dot FIFO. The dot FIFO accepts
data from a Line Loader Unit (LLU) at the system clock rate (pclk),
while the PrintHead Interface (PHI) removes data from the FIFO and
sends it to the printhead at a rate of 2/3 times the system clock
rate.
[0394] In the preferred form, the DRAM is 2.5 Mbytes in size, of
which about 2 Mbytes are available for compressed page store data.
A compressed page is received in two or more bands, with a number
of bands stored in memory. As a band of the page is consumed by the
PEP subsystem 773 for printing, a new band can be downloaded. The
new band may be for the current page or the next page.
[0395] Using banding it is possible to begin printing a page before
the complete compressed page is downloaded, but care must be taken
to ensure that data is always available for printing or a buffer
under-run may occur.
[0396] The embedded USB 1.1 device accepts compressed page data and
control commands from the host PC, and facilitates the data
transfer to either the DRAM (or to another SoPEC device in
multi-SoPEC systems, as described below).
[0397] Multiple SoPEC devices can be used in alternative
embodiments, and can perform different functions depending upon the
particular implementation. For example, in some cases a SoPEC
device can be used simply for its onboard DRAM, while another SoPEC
device attends to the various decompression and formatting
functions described above. This can reduce the chance of buffer
under-run, which can happen in the event that the printer commences
printing a page prior to all the data for that page being received
and the rest of the data is not received in time. Adding an extra
SoPEC device for its memory buffering capabilities doubles the
amount of data that can be buffered, even if none of the other
capabilities of the additional chip are utilized.
[0398] Each SoPEC system can have several quality assurance (QA)
devices designed to cooperate with each other to ensure the quality
of the printer mechanics, the quality of the ink supply so the
printhead nozzles will not be damaged during prints, and the
quality of the software to ensure printheads and mechanics are not
damaged.
[0399] Normally, each printing SoPEC will have an associated
printer unit QA, which stores information relating to the printer
unit attributes such as maximum print speed. The cartridge unit may
also contain a QA chip, which stores cartridge information such as
the amount of ink remaining, and may also be configured to act as a
ROM (effectively as an EEPROM) that stores printhead-specific
information such as dead nozzle mapping and printhead
characteristics. The refill unit may also contain a QA chip, which
stores refill ink information such as the type/colour of the ink
and the amount of ink present for refilling. The CPU in the SoPEC
device can optionally load and run program code from a QA Chip that
effectively acts as a serial EEPROM. Finally, the CPU in the SoPEC
device runs a logical QA chip (ie, a software QA chip).
[0400] Usually, all QA chips in the system are physically
identical, with only the contents of flash memory differentiating
one from the other.
[0401] Each SoPEC device has two LSS system buses that can
communicate with QA devices for system authentication and ink usage
accounting. A large number of QA devices can be used per bus and
their position in the system is unrestricted with the exception
that printer QA and ink QA devices should be on separate LSS
busses.
[0402] In use, the logical QA communicates with the ink QA to
determine remaining ink. The reply from the ink QA is authenticated
with reference to the printer QA. The verification from the printer
QA is itself authenticated by the logical QA, thereby indirectly
adding an additional authentication level to the reply from the ink
QA.
[0403] Data passed between the QA chips is authenticated by way of
digital signatures. In the preferred embodiment, HMAC-SHA1
authentication is used for data, and RSA is used for program code,
although other schemes could be used instead.
[0404] As will be appreciated, the SoPEC device therefore controls
the overall operation of the print engine 1 and performs essential
data processing tasks as well as synchronising and controlling the
operation of the individual components of the print engine Ito
facilitate print media handling, as will be discussed below.
Print Engine
[0405] The print engine 1 is shown in detail in FIGS. 6-8 and
consists of two parts: a cartridge unit 10 and a cradle unit
12.
[0406] As shown, the cartridge unit 10 is shaped and sized to be
received within the cradle unit 12 and secured in position by a
cover assembly 11 mounted to the cradle unit.
[0407] The cradle unit 12 is provided with an external body 13
having anchor portions 14 which allow it to be fixed to the printer
unit 2 in a desired position and orientation, as discussed above,
to facilitate printing.
[0408] In its assembled form as shown in FIG. 8, with cartridge
unit 10 secured within the cradle unit 12 and cover assembly 11
closed, the print engine 1 is able to control various aspects
associated with printing, including transporting the media past the
printhead in a controlled manner as well as the controlled ejection
of ink onto the surface of the passing media. In this regard, the
print engine 2 may also include electrical contacts which
facilitate electrical connection with the user interface 5 of the
printer unit 2 to enable control of the print engine 1.
Cartridge Unit
[0409] The cartridge unit 10 is shown in detail in FIGS. 9-12. With
reference to the exploded views of FIGS. 11 and 12, the cartridge
unit 10 generally consists of a main body 20, a lid assembly 21, a
printhead assembly 22 and a capper assembly 23.
[0410] Each of these parts are assembled together to form an
integral unit which combines ink storage together with the ink
ejection means in a complete manner. Such an arrangement ensures
that the ink is directly supplied to the printhead assembly 22 for
printing, as required, and should there be a need to replace either
or both of the ink storage or the printhead assembly, this can be
readily done by replacing the entire cartridge unit 10.
[0411] As is evident in FIGS. 9 and 10, the cartridge unit 10 has
facilities for receiving a refill supply of ink to replenish the
ink storage when necessary and the cartridge unit itself carries an
integral capping assembly 23 for capping the printhead when not in
use.
Main Body
[0412] The main body 20 of the cartridge unit 10 is shown in more
detail in FIGS. 13-15 and comprises a moulded plastics body which
defines a plurality of ink storage compartments 24 in which the
various colours and/or types of ink are stored. Each of the ink
storage compartments 24 are separated from one another to prevent
mixing of the different inks, as is shown more clearly in FIG. 14,
and extend along the length of the main body 20.
[0413] There are five ink storage compartments 24 shown, having a
square or rectangular shape, with the end compartments being larger
than the other compartments. The larger end compartments are
intended to store the ink more readily consumed during the printing
process, such as black ink or (infrared ink in Netpage
applications) whilst the smaller compartments are intended to store
the cyan, magenta and yellow inks traditionally used in colour
printing. The base 25 of each of the ink storage compartments 24 is
provided with a raised portion 26 which surrounds an ink outlet 27,
through which the ink flows for supply to the printhead assembly
22. The raised portions 26 are typically moulded into the main body
20 and act to separate the outlet 27 from the base 25 of the ink
storage compartment 24 to ensure a sufficient flow rate of ink from
the compartment 24.
[0414] In this regard, an air barrier/ink filter 28 made from a
fine mesh material is placed over the ink outlet 27, atop of the
raised portions 26, thereby leaving a space between the filter and
the outlet for receiving ink. The air barrier/ink filter 28 is
formed such that ink can readily pass through the mesh to the
printhead assembly 22 but any air bubbles present in the ink are
prevented from passing through.
[0415] As shown in FIG. 11, the ink storage compartments 24 are
provided with an absorbent material 29 such as a foam for storing
the ink. The absorbent material 29 is shaped to conform to the
shape of the ink storage compartment 24 and is fitted within the
corresponding compartment to be supported on top of the air
barrier/ink filter 28. In this arrangement, the lower surface of
the absorbent material 29 is separated from the base 25 of the ink
storage compartments via the raised portions 26. The absorbent
material 29 acts to absorb ink supplied to the compartment 24 such
that the ink is suspended internally within. The manner in which
ink is supplied to the compartment 24 will be discussed in more
detail later, however it should be appreciated that the structure
of the absorbent material is such that it contains a number of open
pores which receive and draw in the ink under capillary action.
[0416] The ink fills the space between the ink filter/air barrier
28 and the outlet 27 thereby forming an ink dam, which is in fluid
communication with the ink in the printhead assembly 22 and the ink
suspended within the absorbent material 29. Due to the nature of
the absorbent material 29 and the fact that the ink is retained
therein under capillary action, a back pressure is created which
prevents the ink from freely flowing from the compartment 24 and
out the nozzles of the printhead assembly 22.
[0417] Whilst the use of a foam or sponge material as an absorbent
material 29 which stores the ink therein under capillary attraction
forces is well established in the art, due to the nature of such
materials, their use may cause contaminants to be introduced into
the stored ink. These contaminants can then make their way to the
ink delivery nozzles of the printhead assembly 22, causing
blockages and therefore (possible irreparable) malfunction of the
ink delivery nozzles. Whilst conventional arrangements have
typically employed filters and the like in an attempt to protect
the nozzles, such filters may themselves become blocked due to the
presence of particulate material present in the foam or sponge
material.
[0418] In this regard, in an alternative embodiment, the absorbent
material 29 may be provided as a block or stack of layers made from
a polymer material, such as polycarbonate, acrylic, polysulfone,
polystyrene, fluoropolymer, cyclic olefin polymer, cyclic olefin
copolymer, etc, having the channels 16 formed therein in the form
of a micro-capillary array, as shown in FIG. 16, with each channel
having an average diameter of about 10 microns or less.
[0419] In this arrangement, the body of the absorbent material 29,
in which the micro-capillary array of the channels 16 is formed,
remains stable and rigid at all times. That is, the rigid walls of
the channels remain intact during exposure to the ink whereby
particulate matter is not introduced into the ink, unlike the
cellular or interlaced arrangement of compressible pores within the
conventional foam and sponge materials which contribute to
contaminant production.
[0420] The absorbent material 29 having the channels 16 formed as a
micro-capillary array therein can be arranged within the individual
ink storage compartments 24 as shown in FIG. 17. An ink trapping
layer 17 is provided between the ink filter/air barrier 28 and the
absorbent material 29. The trapping layer 17 absorbs the supplied
ink in multiple-directions, thus allowing for the ingress of the
ink into the longitudinally orientated channels 16, and in this
regard merely acts as a means for presenting the ink to the
channels 16. The trapping layer 17 may be provided as a foam or
sponge material with a thickness substantially less than that of
the absorbent material 29, since the function of the trapping layer
is merely to supply ink to the channels 16 of the absorbent
material 29 and not to store the ink.
[0421] The ink drawn into and stored within the channels 16 is able
to pass to the nozzles of the printhead assembly 22 via the ink
trapping layer 17. The use of foam or sponge material in the ink
trapping layer 17 may result in some particulate contamination
occurring in the ink. However, this may be minimized by providing
the layer with a thickness and density which is just sufficient for
absorbing the necessary amount of ink for effective absorption into
the channels 16. In any event, since the ink is effectively stored
only in the absorbent material 29, the contaminant level that may
be produced in the ink trapping layer is significantly reduced from
the levels produced by the conventional structures.
[0422] A pressed metal chassis 30 is fitted to the underside of the
main body via clips 31 formed in the chassis 30 which mate with
corresponding clips formed in the main body 20. The pressed metal
chassis 30 is shaped to conform to the underside of the main body
20 and includes a plurality of holes 32 that extend therethrough
which are positioned to correspond with the ink outlets 27 of the
ink storage compartments 24 such that there is a passage for ink to
pass through the chassis 30. The chassis 30 provides additional
stability to the cartridge unit 10 and includes an edge 33 that
extends downwardly from the main body 20 which defines a contact
region where the flex printed circuit board 52 of the printhead
assembly 22 contacts with corresponding electrical contacts 128 in
the cradle unit 12, in a manner which will be described in more
detail later in the description. The chassis 30 also has a
plurality of elongate recesses 34 formed along its length, through
which connecting clips provided on the printhead assembly 22 pass,
for connection to the main body 20, as will be described in more
detail below.
[0423] A seal moulding 35 is attached to the chassis 30 to complete
and seal the ink flow path from the ink storage compartments 24
through the chassis 30. The seal moulding 35 is made from an
elastomeric material and has a plurality of hollow cylindrical
inserts 36 formed along its surface which extend through the holes
32 formed in the chassis 30 and into the ink outlets 27 of each of
the ink storage compartments 24, as shown in FIG. 15. The distal
ends of the hollow cylindrical inserts 36 abut with the main body
20 to seal the ink outlets 27 and ensure ink flow through the seal
moulding 35. The seal moulding 35 is fixed to the surface of the
metal chassis 30 by a lock-fit or a suitable adhesive and acts to
provide a substantially planar surface upon which the printhead
assembly 22 is attached. The planar surface having a plurality of
outlet holes 39 provided therein through which ink can flow to the
printhead assembly.
[0424] As is shown in FIGS. 14 and 15 a flex printed circuit board
(PCB) backer 37 is attached to the side of the main body 20 via
locating studs 38 and extends over the downwardly projecting edge
33 of the chassis 30. The flex PCB backer 37 is made from a
suitable elastomeric material and provides a backing onto which the
flex PCB 52 of the printhead assembly 22 is supported following
attachment of the printhead assembly 22 to the main body 20. As
will be discussed in more detail later in the description, the flex
PCB 52 from the printhead assembly 22 is provided with a suitable
recess which fits over the locating studs 38 such that the
electrical dimpled contacts 53 formed on the flex PCB 52 are
positioned over the flex PCB backer 37 and extend outwardly
therefrom to contact suitable electrical contacts 128 provided in
the cradle unit 12. This arrangement provides some degree of
flexibility in this contact region such that appropriate electrical
contact can be established between the cradle unit 12 and the
cartridge unit 10 to allow the transmission of data and power
therebetween to control the ink ejecting nozzles of the printhead
assembly 22. This arrangement also ensures that the forces
associated with the contact between the cartridge unit 12 and the
cradle unit 10 in this region are carried by the chassis 30 and not
transferred to the printhead assembly 22 which could cause damage
to the delicate printhead integrated circuits.
[0425] As shown in FIGS. 13 and 14, the main body 20 also includes
a pair of end supports 40 which extend from the main body 20 in a
downward direction with respect to the cartridge unit 10. The end
supports 40 are arranged such that the seal moulding 35 and the
flex PCB backer 37 extend along the main body 20 between the two
end supports 40. The purpose of the end supports 40 will be
described later in the description.
Printhead Assembly
[0426] The printhead assembly 22 is shown in more detail in FIGS.
18 to 21, and is adapted to be attached to the underside of the
main body 20 to receive ink from the outlet holes 39 formed in the
planar surface of the seal moulding 35.
[0427] As shown more clearly in FIG. 20, the printhead assembly 22
comprises an upper moulding 42, having features which facilitate
connection of the printhead assembly to the main body 20 of the
cartridge unit 10. These features are in the form of u-shaped clips
43 that project from the surface of the upper moulding 42. The
clips 43 pass through the elongate recesses 34 provided in the
chassis 30 and become captured by lugs (not shown) formed in the
main body 20, thereby securing the printhead assembly 22 to the
main body 20.
[0428] In order to receive ink from the ink storage compartments
24, the surface of the upper moulding 42 has a plurality of ink
inlets 44 which project therefrom. The ink inlets 44 are received
within the outlet holes 39 of the seal moulding 35, when the
printhead assembly 22 is secured to the main body 20, and provide a
path for the ink to flow to the printhead integrated circuits for
printing. To ensure a sealed connection, the ink inlets 44 are
shaped to fit within the outlet holes 39 of the seal moulding 35
and may also be provided with an outer coating that facilitates
sealing.
[0429] The upper moulding 42 is made from a liquid crystal polymer
(LCP) and is bonded to a lower moulding 45 via an adhesive film 46.
The lower moulding 45 is also made from an LCP and has a plurality
of channels 47 formed along its length. Each of the channels 47 are
provided to receive ink from one of the ink storage compartments
24, via an ink inlet 44, and distribute the ink along the length of
the printhead assembly 22 for feeding to the ink delivery nozzles
51 of the printhead assembly 22. The channels preferably have a
width of 1 mm and are separated by walls having a width of 0.75 mm.
In the embodiment shown, the lower moulding 45 has five channels 47
extending along its length with each of the ink channels 47
receiving ink from one of the corresponding ink inlets 44. Such an
arrangement ensures that the different inks remain separated
throughout the journey from the individual ink storage compartments
24 to the corresponding ink delivery nozzles of the printhead
integrated circuit. In this regard, the adhesive film 46 also acts
to seal the individual ink channels 47 and prevent cross channel
mixing of the ink when the lower moulding 45 is assembled to the
upper moulding 42.
[0430] In order to further distribute the ink from the ink channels
47 of the lower moulding 45 to the printhead integrated circuits
(ICs) 50, an ink distribution member 48 is attached to the lower
moulding 45 and acts as an interface between the printhead ICs 50
and the ink channels 47 of the lower moulding 45. The purpose of
the ink distribution member 48 is to provide a flow path for ink to
flow from the relatively wide channels 47 to the relatively small
and narrow channels 98 formed on the underside of the printhead ICs
50 which feed the ink to the individual ink delivery nozzles
51.
[0431] In order to appreciate the manner in which the ink
distribution member 48 functions to perform
millimetric-to-micrometric fluid distribution to the nozzles of the
printhead ICs 50, reference is firstly made to the manner in which
the printhead ICs 50 are arranged to form the printing zone of the
printhead assembly 22.
[0432] As alluded to above, the present invention is related to
page-width printing and as such the printhead ICs 50 are arranged
to extend horizontally across the width of the passing media to
deposit ink droplets thereon to create an image. To achieve this,
individual printhead ICs 50 are linked together in abutting
arrangement across the surface of the ink distribution member 48 of
the printhead assembly 22, as shown simply in FIG. 22. The length
of an individual printhead IC 50 is around 20-22 mm and as such in
order to print an A4/US letter sized page, 11-12 individual
printhead ICs 50 may be linked together in abutting fashion. Other
printing sizes may also be possible and as such the number of
individual printhead ICs 50 required may vary depending upon the
application.
[0433] Each printhead IC 50 has a plurality of individual ink
delivery nozzles 51 formed therein, the structure and control of
which will be described in more detail later. The nozzles 51 within
an individual printhead IC 50 are grouped physically to reduce ink
supply complexity and wiring complexity, and are also grouped
logically to minimize power consumption and to allow a variety of
printing speeds.
[0434] As mentioned previously, each printhead IC 50 is able to
print five different colours (C, M, Y, K and IR) and contains 1280
ink delivery nozzles 51 per colour, with these nozzles being
divided into even and odd nozzles (640 each). Even and odd nozzles
for each colour are provided on different rows on the printhead IC
50 and are aligned vertically to perform true 1600 dpi printing,
meaning that the nozzles 51 are arranged in 10 rows. The horizontal
distance between two adjacent nozzles 51 on a single row is 31.75
microns, whilst the vertical distance between rows of nozzles is
based on the firing order of the nozzles, but rows are typically
separated by an exact number of dot lines, plus a fraction of a dot
line corresponding to the distance the paper will move between row
firing times Also, the spacing of even and odd rows of nozzles for
a given colour must be such that they can share an ink channel, as
will be described below.
[0435] The manner in which individual printhead ICs 50 are linked
together in abutting fashion may be performed in a variety of ways.
As shown in FIG. 23, the simplest way to achieve this linkage of
the printhead ICs 50 is to form a rectangular join between adjacent
ICs 50. However, due to the nature of this rectangular join, it may
result in a gap between adjacent nozzles at the join interface
which could produce a vertical stripe down the printed page of
media where no ink is deposited, which may be unacceptable in some
printing applications.
[0436] This may be overcome by providing a sloping join as shown in
FIG. 24a which provides nozzle overlap at the join interface. As
shown by the enlarged view of nozzle rows of a single colour at the
interface in FIG. 24b, such an arrangement does not produce a
visible join along the printing page as discussed above. In this
arrangement, the ICs 50 must be perfectly aligned vertically to
link in this fashion and as such this may not be always
possible.
[0437] To overcome this problem, the ICs 50 may be provided with a
vertical offset, as shown in FIG. 25. This offset can be seen by
the vertical offset between the longitudinal edges of adjacent ICs
50, and this offset increases with each join along the length of
the printhead assembly 22. For example, if the offset was
equivalent to 7 lines of nozzles per join, then for 11 ICs joined
in this manner, there would be a total of 10 joins and 70
additional nozzle lines. This then results in an increase in the
lines of data storage required for the printhead assembly. To
overcome this, each IC 50 may be placed on a mild slope to achieve
a constant number of print lines regardless of the number of joins,
as shown in FIG. 26. It will be appreciated that in this
arrangement the rows of nozzles on the ICs 50 are aligned, but the
IC is placed in a sloped orientation, such that if all the nozzles
were fired at once, the effect would be lots of sloped lines
provided on the page of media, however with the nozzles being fired
in the correct order relative to the paper movement, a straight
line for n dots would be printed, followed by another straight line
for another n dots separated by 1 line.
[0438] Yet another system for linking the ICs 50 in abutting
fashion is shown in FIGS. 27a and 27b. In this arrangement, the ICs
50 are shaped at their ends to link together to form a horizontal
line of ICs, with no vertical offset between neighboring ICs. A
sloping join is provided between the ICs which has a 45 degree
angle to the upper and lower chip edges. Typically, the joining
edge is not straight and has a sawtooth profile to facilitate
positioning, and the ICs 50 are intended to be spaced about 11
microns apart, measured perpendicular to the joining edge. In this
arrangement, the left most ink delivery nozzles on each row are
dropped by 10 line pitches and arranged in a triangle configuration
as shown in FIG. 27a and FIGS. 28a and 28b. This arrangement
provides a degree of overlap of nozzles at the join and maintains
the pitch of the nozzles to ensure that the drops of ink are
delivered consistently along the printing zone. This arrangement
also ensures that more silicon is provided at the edge of the IC 50
to ensure sufficient linkage. Control of the operation of the
nozzles is performed by the SoPEC device, however compensation for
the nozzles is performed in the printhead, or may also be performed
by the SoPEC device, depending on the storage requirements. In this
regard it will be appreciated that the dropped triangle arrangement
of nozzles disposed at one end of the IC 50 provides the minimum
on-printhead storage requirements. However where storage
requirements are less critical shapes other than a triangle can be
used, for example, the dropped rows may take the form of a
trapezoid.
[0439] FIG. 28a shows more clearly the upper surface of a portion
of the individual ICs. As can be seen bond pads 96 are provided
along an edge thereof which provide a means for receiving data and
or power to control the operation of the nozzles from the SoPEC of
the cradle unit 12. Fiducials 97 are also provided on the surface
of the ICs to assist in positioning and aligning the ICs 50 with
respect to each other. The fiducials 97 are in the form of markers
that are readily identifiable by appropriate positioning equipment
to indicate the true position of the IC 50 with respect to a
neighbouring IC 50, and are strategically positioned at the edges
of the IC, proximal the join. As shown in FIG. 28b, the fiducials
97 align with corresponding fiducials 97 provided on the surface of
a neighbouring IC 50 to ensure alignment of the ICs to appropriate
limits, as discussed above.
[0440] The underside of a printhead IC 50 is shown in relation to
FIG. 28c. As shown, along the underside of the IC 50 there are
provided a number of etched channels 98, with each channel 98 in
communication with a pair of rows of nozzles 51. The channels 98
are about 80 microns wide and extend the length of the IC 50 and
include silicon walls 99 formed therein, to divide the channels 98
into portions. The channels are adapted to receive ink from the ink
channels 47 of the lower moulding 45 and distribute the ink to the
pair of rows of nozzles 51 to eject that ink of a specific colour
or type. The partitioning of the channels 98 by the silicon walls
99 ensures that the flow path to the nozzles is not too great
thereby reducing the likelihood of ink starvation to the individual
nozzles along the length of the IC. In this regard, each portion
feeds approximately 128 nozzles and is individually fed a supply of
ink.
[0441] Each of the ICs 50 are positioned and secured to the surface
of the ink distribution member 48. As mentioned previously, the ink
distribution member delivers the ink from the 1 mm wide channels 47
formed in the lower moulding 45 to the 80 micron wide channels 98
formed in the underside of the printhead ICs 50.
[0442] The ink distribution member 48 can be configured in a number
of forms. In one embodiment the ink distribution member 48 may be
in the form of a laminated structure consisting of a number of
layers bonded to one another, as described in U.S. Pat. No.
6,409,323 and pending US Application No. 2004/0113997.
[0443] In an alternative embodiment, the ink distribution member 48
may be in a two-part form comprising an intermediate layer 172 and
an adhesive layer 173, as shown in FIG. 29. In this arrangement,
the intermediate layer 172 is arranged to fit over the exposed
channels 47 of the lower moulding 45 to seal the channels 47 and to
form a sealed unit with the lower moulding 45. The intermediate
layer 172 has a plurality of holes 174 formed therethrough along
its length each of which are aligned with the channels 47 and are
spaced at regular intervals along the length thereof.
[0444] As shown more clearly in FIG. 30, the holes 174 formed
through the intermediate layer 172 which relate to the most central
channel 47 of the lower moulding 45 are in the form of small
diameter holes equi-spaced at intervals along the length of the
intermediate layer 172. Larger diameter holes 174 are provided
which correspond to the other channels 47 of the lower moulding 45,
which are displaced laterally from the most central channel. These
holes 174 are similarly equi-spaced along the length of the
intermediate layer and micro conduits 176 are provided which extend
from the larger diameter holes to terminate at a central region of
the intermediate layer 172, proximal the smaller diameter holes.
These conduits 176 distribute the ink from each of the holes 172 to
a central region of the intermediate layer to deliver the different
types/colours of ink to the channels 98 formed in the underside of
the integrated circuits 50.
[0445] The intermediate layer 172 is also made from a liquid
crystal polymer (LCP) which is injection moulded to the appropriate
shape and configuration. The intermediate layer 172 is bonded to
the lower moulding 45 via a thermal adhesive, such as 3M 816 or
Abelflex 5206 or 5205, which is applied between the intermediate
layer 172 and the lower moulding 45 and placed in a laminator.
[0446] To facilitate placement and to secure the integrated
circuits 50 upon the surface of the intermediate layer 172 a
bonding film 175 is applied to the surface of the intermediate
layer 172. The bonding film 175 is in the form of a laminate
polymer film which may be a thermoplastic film such as a PET or
Polysulphone film, or it may be in the form of a thermoset film,
such as those manufactured by AL technologies and Rogers
Corporation. The bonding film 175 preferably has co-extruded
adhesive layers formed on both sides thereof and is laminated onto
the upper surface of the intermediate layer 172
[0447] Following lamination of the bonding layer 175 to the
intermediate layer 172, holes are drilled through the bonding layer
175 to coincide with the centrally located small diameter holes
174, and the ends of the conduits 176. This is shown in FIG. 31.
These holes provide a separate flow passage through the bonding
layer 175 for each of the different types of inks, which feed
directly to the appropriate channel portions 98 formed on the
underside of the integrated circuits 50 for supply to the ink
delivery nozzles 51 associated with each channel portion 98, as
discussed above. Fiducial locating marks 177 are also drilled into
the surface of the bonding layer to assist in attaching and
positioning the ICs 50 thereon.
[0448] In order to attach the ICs 50 to the surface of the bonding
layer 175, the ICs 50 are placed in a die and heated to 170.degree.
C. and then pressed into the bonding layer 175 at 40 psi pressure
for about 3 seconds. This results in the ICs 50 being thermally
bonded to the intermediate layer 172, as shown in FIG. 32. As
shown, the fiducial locating marks 177 formed in the surface of the
bonding layer 175 aid in positioning the ICs such that the channels
98 formed in the underside of the ICs 50 correctly align with the
holes drilled through the bonding layer 175 to provide a flow path
for ink to be fed to the nozzles for printing.
[0449] In this embodiment the ink distribution member 48 is in the
form of a two part element containing an intermediate layer 172
which fits over the channels 47 formed in the lower moulding 45,
and a bonding layer 175 allowing fluid flow therethrough and which
acts to attach the ICs to the surface of the intermediate layer
172.
[0450] In yet another embodiment, the ink distribution member 48
may be in the form of a one-piece element with the ICs being
directly attached to its upper surface. In this regard, rather than
providing an intermediate layer 172 having holes 174 that extend
therethrough and conduits 176 formed in the upper surface thereof
to direct the flow of ink towards the central region of the
intermediate layer 172, the conduits are formed within the body of
the ink distribution member 48 such that the upper surface of the
ink distribution member only has small diameter holes formed
centrally therein for delivering the ink to the undersurface of the
ICs.
[0451] The manner in which this is achieved is shown in FIGS.
33a-33c. These Figures merely show the manner in which the ink can
be directed from one of the channels 47 of the lower moulding 45,
and it will be appreciated that the same approach can be similarly
applied to deliver ink from the remainder of the channels 47.
[0452] As shown, the underside of the ink distribution member 48 is
provided with a plurality of holes or inlets 180 therein, each
having a diameter of approximately 1 mm, which corresponds to the
width of the channels 47 provided in the lower moulding 45. The
inlets 180 do not extend through the body of the ink distribution
member 48, but rather extend into the member 48 to a depth of about
a 3/4 the thickness of the member 48, as shown in the sectioned
view of FIG. 33c.
[0453] For the inlets 180 associated with the centre channel 47 of
the lower moulding, an outlet 182, in the form of a 80 micron wide
hole, is provided in the uppermost surface of the ink distribution
member 48 which extends into the end wall of the inlet 180 to
provide a path for the ink to flow out of the ink distribution
member. For the inlets 180 associated with the other channels 47 of
the lower moulding 45, a tunnel 181 is provided from a side wall of
the inlet 180 within the ink distribution member 48 which acts to
direct the flow of the ink received in the inlet through the body
of the ink distribution member 48 to a central position therein. An
outlet 182, as described above, is then formed on an uppermost side
of the ink distribution member to provide a path for the ink
present in the tunnel 181 to exit the ink distribution member at
the desired position along the surface of the ink distribution
member. The outlets 182 are essentially 80 microns in width, to
correspond with the width of the channels 98 provided on the
underside of the integrated circuits 50.
[0454] The ink distribution member 48 of this embodiment is made
from a photo-structurable glass-ceramic material, such as Forturan
glass. These materials, when exposed to specific levels of pulsed
UV laser energy density (fluence), have a photo-chemical reaction
which creates a density of nanocrystals within the volume thereof,
the density of which is directly proportional to the fluence of the
exposed laser beam. In this regard, in order to form the desired
inlets 180, outlets 182 and tunnels 181 connecting the inlets and
outlets, the ink distribution member 48 is mounted upon a precision
XYZ stage for exposure to a focussed laser beam. Various tools may
be used to control the size and shape of the critically exposed
volume of the glass structure to ensure that the desired pattern
and shape is created within the ink distribution member. Typical
exposure times may vary from 15 minutes to 1 hour.
[0455] Following exposure the ink distribution member is loaded
into an oven for thermal treatment to aid in causing
crystallisation of exposed regions of the glass. The exposed and
thermally treated glass is then loaded into a mild etchant for
around 7 minutes to etch the exposed regions, however the etch time
may vary dependant upon the thickness of the glass and the depth of
the cut. The thermal treatment and etching steps may be repeated in
order to form the complete ink distribution member as shown in the
figures.
[0456] With this arrangement, ink present in the channels 47 of the
lower moulding 45 is drawn into the ink distribution member 48 via
inlets 180 which are positioned over the channels 47 at regular
intervals therealong. Upon entering the inlets 180, where required,
the ink is directed to a central region of the ink distribution
member 48 via the above mentioned tunnels 181, where the ink can
then exit the ink distribution member 48 via the outlets 182 at a
predetermined position which is aligned with the corresponding
channels 98 formed in the underside of the ICs 50.
[0457] The ICs 50 are secured to the upper surface of the ink
distribution member 48 to receive the ink therefrom, using spun
coated adhesive applied to the underside of the IC 50, or by screen
printing epoxy on the upper surface of the ink distribution member
48. In this regard, the fiducials provided on the ICs 50 and on the
surface of the ink distribution member 48 assist in positioning the
ICs 50 such that the channels 98 formed in the underside of the ICs
50 are aligned with the appropriate outlet 182 formed in the upper
surface of the member 48 to receive the correct type/colour of
ink.
[0458] FIGS. 34a and 34b show the manner in which this is arranged
to control the delivery of ink from the five channels 47 of the
lower moulding 45. These figures provide a top view of the
arrangement and for reasons of clarity, the various elements are
shown in outline to indicate the manner in which ink flows between
the elements. FIG. 34a is a top view of the arrangement showing the
ICs 50 located centrally upon the ink distribution member 48. The
ink distribution member 48 is in turn secured to the lower moulding
45 such that the inlets 180 align with the respective channels 47
at regular intervals along the length thereof to receive ink from
the channels 47 for distribution to the ICs 50. The inlets 180
associated with the central channel 47 are in direct fluid
communication with an outlet 182, which delivers the ink to the
underside of the ICs 50. The inlets 180 associated with the other
channels 47 include tunnels 181 formed within the ink distribution
member 48 which are in fluid communication with associated outlets
182 disposed remote from the inlets 180 to deliver ink to the
underside of the ICs 50. As is shown, in this arrangement the
outlets 182 are centrally arranged on the upper surface of the ink
distribution member in a predetermined pattern, with the position
of each outlet defining a point at which ink of a specific colour
is delivered to the IC 50.
[0459] FIG. 34b is a magnified view of FIG. 34a, showing in detail
the manner in which the ink is supplied to the underside of the ICs
50. The channels 98 formed on the underside of the IC 50 are
clearly shown, as are the silicon walls 99 provided along the
length of the channels 98, which divide the channels 98 into
portions. As shown, the ICs 50 are positioned on the surface of the
ink distribution member such that the outlets 182 align with the
channels 98 at the junction of the channel portions, namely at the
region where the silicon walls 99 are situated. This then ensures
that one outlet 182 supplies ink to two channel portions, allowing
a regular spacing of outlets to be achieved along the surface of
the ink distribution member 48.
[0460] In the above described embodiment, the ink distribution
member 48 is in the form of a on-piece element thereby overcoming
the need to provide separate layers and reducing the complexity of
the system, as sealing between layers is no longer required.
[0461] Following attachment and alignment of each of the printhead
ICs 50 to the surface of the ink distribution member 48, a flex PCB
52 is attached along an edge of the ICs 50 so that control signals
and power can be supplied to the bond pads 96 of the ICs 50 to
effect printing. As shown more clearly in FIG. 20, the flex PCB 52
folds around the printhead assembly 22 in an upward direction with
respect to the cartridge unit 10, and has a plurality of dimpled
contacts 53 provided along its length for receiving power and or
data signals from the control circuitry of the cradle unit 12. A
plurality of holes 54 are also formed along the distal edge of the
flex PCB 52 which provide a means for attaching the flex PCB 52 to
the locating studs 38 formed on the main body 20, such that the
dimpled contacts 53 of the flex PCB 52 extends over the flex PCB
backer 37. The manner in which the dimpled contacts 53 of the flex
PCB 52 contact the power and data contacts 128 of the cradle unit
12 is described later.
[0462] A media shield 55 is attached to the printhead assembly 22
along an edge thereof and acts to protect the printhead ICs 50 from
damage which may occur due to contact with the passing media. The
media shield 55 is attached to the upper moulding 42 upstream of
the printhead ICs 50 as shown more clearly in FIG. 21, via an
appropriate clip-lock arrangement or via an adhesive. When attached
in this manner, the printhead ICs 50 sit below the surface of the
media shield 55, out of the path of the passing media.
[0463] As shown in FIGS. 20 and 21, a space 56 is provided between
the media shield 55 and the upper 42 and lower 45 moulding which
can receive pressurized air from an air compressor or the like. As
this space 56 extends along the length of the printhead assembly
22, compressed air can be supplied to the space 56 from either end
of the printhead assembly 22 and be evenly distributed along the
assembly. The inner surface 57 of the media shield 55 is provided
with a series of fins 58 which define a plurality of air outlets
evenly distributed along the length of the media shield 55 through
which the compressed air travels. This arrangement therefore
provides a stream of air across the printhead ICs 50 in the
direction of the media delivery which acts to prevent dust and
other particulate matter carried with the media from settling on
the surface of the printhead ICs, which could cause blockage and
damage to the nozzles.
[0464] A cross section of the complete printhead assembly 22 is
shown in FIG. 21. As shown, ink is received from the ink storage
compartments 24 via the ink inlets 44 of the upper moulding 42,
which feed the ink directly into one of the ink channels 47 of the
lower moulding 45. The ink is in turn fed from the ink channels 47
to the ink delivery nozzles 51 of the printhead ICs 50 by way of
the ink distribution member 48.
[0465] As shown in FIGS. 20 and 21, the lower moulding 45 is
provided with a plurality of priming inlets 59 at one end thereof.
Each of the priming inlets 59 communicate directly with one of the
channels 47 and provide a means for priming the printhead assembly
22 and the ink storage compartments 24 with ink prior to shipment
and use. Various ways in which the priming is achieved will now be
described with reference to FIGS. 35-40.
[0466] FIG. 35 is a simplified cross-sectional representation of an
ink storage compartment 24 as described previously. Ink is primed
into the absorbent material 29 through the ink outlet 27 which
links the compartment 24 to the channels 47 of the printhead
assembly 22. In this regard, the ink is supplied via the priming
inlets 59 along the channels 47 of the lower moulding 45, with each
channel 47 in fluid communication with one ink outlet 27 of an ink
storage compartment 24 to deliver ink of a specific type/colour to
that ink storage compartment 24.
[0467] Priming of the ink storage compartments 24 is typically
performed prior to shipment of the cartridge unit 10 and as such,
an ink source can be temporarily attached to the priming inlets 59,
wherein upon completion of priming, the priming inlets can be
capped/sealed.
[0468] As discussed above, priming ink is supplied under pressure
to the ink storage compartment 24 via the ink outlets 27. The
priming ink flows into the space between the ink filter/air barrier
28 and the outlet 27, and is absorbed into the absorbent material
29 through the ink filter/air barrier 28. As discussed above, due
to the porous nature of the absorbent material 29 the ink becomes
suspended within the absorbent material due to capillary attraction
forces. By keeping the upper surface of the absorbent material 29
dry and exposed to atmospheric pressure through the vent hole 63,
the ink is able to be continually drawn into the pores of the
absorbent material 29 via capillary action (as shown by arrows
B).
[0469] As discussed above, ink present in the channels 47 of the
lower moulding 45 is also supplied to the ink delivery nozzles 51
of the integrated circuits 50, via the ink distribution member 48.
During the above described priming process, the ink flows to the
nozzles 51 to prime the individual nozzles with ink, and due to the
capillary action of the absorbent material 29 in the ink storage
compartments 24, a sufficient backpressure is established in the
ink supply to prevent leakage of the ink out of the nozzles 51.
[0470] In this regard, the priming operation is ceased before the
absorbent material becomes completely saturated and its upper
surface becomes wet with ink, so that the necessary backpressure
can be maintained. This may be controlled by limiting the supply of
ink or by more sophisticated methods, such as sensing the level of
ink within the body. Hydrophobic material may also be used on the
surface of the ICs 50 in the vicinity of the nozzles 51 so as to
assist in leakage prevention.
[0471] In the above-described arrangement, it may be necessary to
maintain the pressure of the supplied ink to be below a level which
ensures the ink is not ejected through the nozzle outlets 51 during
priming. Practically, this situation may increase the required time
necessary to prime the cartridge unit 10.
[0472] An alternative embodiment for configuring the ink storage
compartments 24 which provides a means of substantially obviating
the need to limit the ink pressure during priming is illustrated in
FIGS. 35 to 39. In this embodiment, a bypass fluid path 185 is
provided in fluid communication with the ink outlet 27.
[0473] The bypass fluid path 185 allows the priming ink an
additional path into the ink storage compartment 24 where it can be
absorbed by the absorbent material 29. In this regard, the priming
ink does not only flow through the ink filter air barrier 28
directly into the absorbent material 29, but can also flow into at
least a portion of a well region 24a of the compartment 24, as
illustrated by arrows C in FIG. 36. The well region 24a is the
annular region surrounding the raised portions 26 on the base 25 of
the compartments where there is a gap between the base 25 of the
compartment 24 and the absorbent material 29. This well region 24a
defines a space where the priming ink can be readily delivered via
the bypass fluid path 185.
[0474] With this arrangement, by providing more than one path for
the ink to enter the ink storage compartment 24, a larger surface
area of the absorbent material 29 is exposed to the priming ink and
as such the ink is drawn into the absorbent material more quickly
and the supply pressure of the priming ink can be reduced.
[0475] The path 185 is provided with a bypass valve 186 which is
open during initial priming of the cartridge unit 10 and is closed
upon completion of the priming operation, as shown in FIG. 37. The
bypass valve 186 may be provided by way of a variety of
arrangements and may be either manually or automatically
controlled. For example, the bypass valve 186 may be provided as a
manual depression button as illustrated in FIGS. 38 and 39.
[0476] In this arrangement, the bypass valve 186 is in the form of
a button 187 provided as a flexible portion of the bottom wall of
the path 185. The button 187 may be made from a rubber material and
may be connected to the wall of the path 185 via an annular
weakened portion 187a. Initially, and during priming, the button
187 is positioned as shown in FIG. 38 to allow the priming ink to
flow through the path 185. Once priming is complete, the path 185
is closed by depressing the button 187 into a circular recessed
region 188 of the internal wall of the path 185. In this regard,
the button 187 is captured by the lip 189 and retained therein,
thereby blocking the bypass valve 186, as shown in FIG. 39.
[0477] It will be appreciated that those skilled in the art will
understand that other bypass valve structures are possible and
encompassed by the present invention. For example, a simple
alternative to the above may be providing the additional fluid path
185 as a compressible silicon tube or the like.
[0478] The bypass valve 186 may be configured to be irreversibly
closed once the priming is completed. On the other hand, if
refilling of the storage compartments via the priming inlets of the
printhead assembly 22 is desired, a bypass valve capable of being
opened and closed without limit may be provided.
[0479] Another embodiment of the ink storage compartments 24 which
provides an alternative or additional arrangement for priming the
compartments 24 with ink is illustrated in FIG. 40.
[0480] In this arrangement, a port 190 is provided in at least one
of the side walls of each compartment 24 in a position below the
upper surface of the absorbent material 29. The ports 190 are
provided for the insertion of a needle 191 from an external ink
source syringe or the like (not shown) which penetrates into the
absorbent material 29, and through which the priming ink is
supplied into the body. The ports 190 are configured so that the
needle 191 supplies the priming ink towards the lower portion of
the absorbent material 29, shown with arrows D in FIG. 40, so as to
prevent wetting of the uppermost portion of the absorbent material
29, for the reasons discussed above.
[0481] Each port 190 is provided with a valve 192 which allows
penetration of the needle 191 and is sealed when the needle is
extracted and at other times. For example, the valve 192 may
incorporate an elastomeric seal.
[0482] In this way, the priming ink is delivered directly to the
absorbent material 29 and through capillary force is suspended
therein for delivery to the nozzles of the printhead assembly 22,
as shown with arrow E in FIG. 40.
[0483] The arrangement of this embodiment may be provided
independently of those of the above-described embodiments, or may
be used in conjunction with those arrangements to provide an
additional refilling mechanism for the ink storage compartments
24.
Ink Delivery Nozzles
[0484] An example of a type of ink delivery nozzle arrangement
suitable for the present invention, comprising a nozzle and
corresponding actuator, will now be described with reference to
FIGS. 41 to 50. FIG. 50 shows an array of ink delivery nozzle
arrangements 801 formed on a silicon substrate 8015. Each of the
nozzle arrangements 801 are identical, however groups of nozzle
arrangements 801 are arranged to be fed with different colored inks
or fixative. In this regard, the nozzle arrangements are arranged
in rows and are staggered with respect to each other, allowing
closer spacing of ink dots during printing than would be possible
with a single row of nozzles. Such an arrangement makes it possible
to provide a high density of nozzles, for example, more than 5000
nozzles arrayed in a plurality of staggered rows each having an
interspacing of about 32 microns between the nozzles in each row
and about 80 microns between the adjacent rows. The multiple rows
also allow for redundancy (if desired), thereby allowing for a
predetermined failure rate per nozzle.
[0485] Each nozzle arrangement 801 is the product of an integrated
circuit fabrication technique. In particular, the nozzle
arrangement 801 defines a micro-electromechanical system
(MEMS).
[0486] For clarity and ease of description, the construction and
operation of a single nozzle arrangement 801 will be described with
reference to FIGS. 41 to 49.
[0487] The ink jet printhead integrated circuit 50 includes a
silicon wafer substrate 8015 having 0.35 Micron 1 P4M 12 volt CMOS
microprocessing electronics is positioned thereon.
[0488] A silicon dioxide (or alternatively glass) layer 8017 is
positioned on the substrate 8015. The silicon dioxide layer 8017
defines CMOS dielectric layers. CMOS top-level metal defines a pair
of aligned aluminium electrode contact layers 8030 positioned on
the silicon dioxide layer 8017. Both the silicon wafer substrate
8015 and the silicon dioxide layer 8017 are etched to define an ink
inlet channel 8014 having a generally circular cross section (in
plan). An aluminium diffusion barrier 8028 of CMOS metal 1, CMOS
metal 2/3 and CMOS top level metal is positioned in the silicon
dioxide layer 8017 about the ink inlet channel 8014. The diffusion
barrier 8028 serves to inhibit the diffusion of hydroxyl ions
through CMOS oxide layers of the drive electronics layer 8017.
[0489] A passivation layer in the form of a layer of silicon
nitride 8031 is positioned over the aluminium contact layers 8030
and the silicon dioxide layer 8017. Each portion of the passivation
layer 8031 positioned over the contact layers 8030 has an opening
8032 defined therein to provide access to the contacts 8030.
[0490] The nozzle arrangement 801 includes a nozzle chamber 8029
defined by an annular nozzle wall 8033, which terminates at an
upper end in a nozzle roof 8034 and a radially inner nozzle rim 804
that is circular in plan. The ink inlet channel 8014 is in fluid
communication with the nozzle chamber 8029. At a lower end of the
nozzle wall, there is disposed a moving rim 8010, that includes a
moving seal lip 8040. An encircling wall 8038 surrounds the movable
nozzle, and includes a stationary seal lip 8039 that, when the
nozzle is at rest as shown in FIG. 44, is adjacent the moving rim
8010. A fluidic seal 8011 is formed due to the surface tension of
ink trapped between the stationary seal lip 8039 and the moving
seal lip 8040. This prevents leakage of ink from the chamber whilst
providing a low resistance coupling between the encircling wall
8038 and the nozzle wall 8033.
[0491] As best shown in FIG. 48, a plurality of radially extending
recesses 8035 is defined in the roof 8034 about the nozzle rim 804.
The recesses 8035 serve to contain radial ink flow as a result of
ink escaping past the nozzle rim 804.
[0492] The nozzle wall 8033 forms part of a lever arrangement that
is mounted to a carrier 8036 having a generally U-shaped profile
with a base 8037 attached to the layer 8031 of silicon nitride.
[0493] The lever arrangement also includes a lever arm 8018 that
extends from the nozzle walls and incorporates a lateral stiffening
beam 8022. The lever arm 8018 is attached to a pair of passive
beams 806, formed from titanium nitride (TiN) and positioned on
either side of the nozzle arrangement, as best shown in FIGS. 44
and 49. The other ends of the passive beams 806 are attached to the
carrier 8036.
[0494] The lever arm 8018 is also attached to an actuator beam 807,
which is formed from TiN. It will be noted that this attachment to
the actuator beam is made at a point a small but critical distance
higher than the attachments to the passive beam 806.
[0495] As best shown in FIGS. 41 and 47, the actuator beam 807 is
substantially U-shaped in plan, defining a current path between the
electrode 809 and an opposite electrode 8041. Each of the
electrodes 809 and 8041 are electrically connected to respective
points in the contact layer 8030. As well as being electrically
coupled via the contacts 809, the actuator beam is also
mechanically anchored to anchor 808. The anchor 808 is configured
to constrain motion of the actuator beam 807 to the left of FIGS.
44 to 46 when the nozzle arrangement is in operation.
[0496] The TiN in the actuator beam 807 is conductive, but has a
high enough electrical resistance that it undergoes self-heating
when a current is passed between the electrodes 809 and 8041. No
current flows through the passive beams 806, so they do not
expand.
[0497] In use, the device at rest is filled with ink 8013 that
defines a meniscus 803 under the influence of surface tension. The
ink is retained in the chamber 8029 by the meniscus, and will not
generally leak out in the absence of some other physical
influence.
[0498] As shown in FIG. 42, to fire ink from the nozzle, a current
is passed between the contacts 809 and 8041, passing through the
actuator beam 807. The self-heating of the beam 807 due to its
resistance causes the beam to expand. The dimensions and design of
the actuator beam 807 mean that the majority of the expansion in a
horizontal direction with respect to FIGS. 41 to 43. The expansion
is constrained to the left by the anchor 808, so the end of the
actuator beam 807 adjacent the lever arm 8018 is impelled to the
right.
[0499] The relative horizontal inflexibility of the passive beams
806 prevents them from allowing much horizontal movement the lever
arm 8018. However, the relative displacement of the attachment
points of the passive beams and actuator beam respectively to the
lever arm causes a twisting movement that causes the lever arm 8018
to move generally downwards. The movement is effectively a pivoting
or hinging motion. However, the absence of a true pivot point means
that the rotation is about a pivot region defined by bending of the
passive beams 806.
[0500] The downward movement (and slight rotation) of the lever arm
8018 is amplified by the distance of the nozzle wall 8033 from the
passive beams 806. The downward movement of the nozzle walls and
roof causes a pressure increase within the chamber 8029, causing
the meniscus to bulge as shown in FIG. 42. It will be noted that
the surface tension of the ink means the fluid seal 8011 is
stretched by this motion without allowing ink to leak out.
[0501] As shown in FIG. 43, at the appropriate time, the drive
current is stopped and the actuator beam 807 quickly cools and
contracts. The contraction causes the lever arm to commence its
return to the quiescent position, which in turn causes a reduction
in pressure in the chamber 8029. The interplay of the momentum of
the bulging ink and its inherent surface tension, and the negative
pressure caused by the upward movement of the nozzle chamber 8029
causes thinning, and ultimately snapping, of the bulging meniscus
to define an ink drop 802 that continues upwards until it contacts
adjacent print media.
[0502] Immediately after the drop 802 detaches, meniscus 803 forms
the concave shape shown in FIG. 43. Surface tension causes the
pressure in the chamber 8029 to remain relatively low until ink has
been sucked upwards through the inlet 8014, which returns the
nozzle arrangement and the ink to the quiescent situation shown in
FIG. 61.
[0503] Another type of printhead nozzle arrangement suitable for
the present invention will now be described with reference to FIG.
51. Once again, for clarity and ease of description, the
construction and operation of a single nozzle arrangement 1001 will
be described.
[0504] The nozzle arrangement 1001 is of a bubble forming heater
element actuator type which comprises a nozzle plate 1002 with a
nozzle 1003 therein, the nozzle having a nozzle rim 1004, and
aperture 1005 extending through the nozzle plate. The nozzle plate
1002 is plasma etched from a silicon nitride structure which is
deposited, by way of chemical vapor deposition (CVD), over a
sacrificial material which is subsequently etched.
[0505] The nozzle arrangement includes, with respect to each nozzle
1003, side walls 1006 on which the nozzle plate is supported, a
chamber 1007 defined by the walls and the nozzle plate 1002, a
multi-layer substrate 1008 and an inlet passage 1009 extending
through the multi-layer substrate to the far side (not shown) of
the substrate. A looped, elongate heater element 1010 is suspended
within the chamber 1007, so that the element is in the form of a
suspended beam. The nozzle arrangement as shown is a
microelectromechanical system (MEMS) structure, which is formed by
a lithographic process.
[0506] When the nozzle arrangement is in use, ink 1011 from a
reservoir (not shown) enters the chamber 1007 via the inlet passage
1009, so that the chamber fills. Thereafter, the heater element
1010 is heated for somewhat less than 1 micro second, so that the
heating is in the form of a thermal pulse. It will be appreciated
that the heater element 1010 is in thermal contact with the ink
1011 in the chamber 1007 so that when the element is heated, this
causes the generation of vapor bubbles in the ink. Accordingly, the
ink 1011 constitutes a bubble forming liquid.
[0507] The bubble 1012, once generated, causes an increase in
pressure within the chamber 1007, which in turn causes the ejection
of a drop 1016 of the ink 1011 through the nozzle 1003. The rim
1004 assists in directing the drop 1016 as it is ejected, so as to
minimize the chance of a drop misdirection.
[0508] The reason that there is only one nozzle 1003 and chamber
1007 per inlet passage 1009 is so that the pressure wave generated
within the chamber, on heating of the element 1010 and forming of a
bubble 1012, does not effect adjacent chambers and their
corresponding nozzles.
[0509] The increase in pressure within the chamber 1007 not only
pushes ink 1011 out through the nozzle 1003, but also pushes some
ink back through the inlet passage 1009. However, the inlet passage
1009 is approximately 200 to 300 microns in length, and is only
approximately 16 microns in diameter. Hence there is a substantial
viscous drag. As a result, the predominant effect of the pressure
rise in the chamber 1007 is to force ink out through the nozzle
1003 as an ejected drop 1016, rather than back through the inlet
passage 1009.
[0510] As shown in FIG. 51, the ink drop 1016 is being ejected is
shown during its "necking phase" before the drop breaks off. At
this stage, the bubble 1012 has already reached its maximum size
and has then begun to collapse towards the point of collapse
1017.
[0511] The collapsing of the bubble 1012 towards the point of
collapse 1017 causes some ink 1011 to be drawn from within the
nozzle 1003 (from the sides 1018 of the drop), and some to be drawn
from the inlet passage 1009, towards the point of collapse. Most of
the ink 1011 drawn in this manner is drawn from the nozzle 1003,
forming an annular neck 1019 at the base of the drop 16 prior to
its breaking off.
[0512] The drop 1016 requires a certain amount of momentum to
overcome surface tension forces, in order to break off. As ink 1011
is drawn from the nozzle 1003 by the collapse of the bubble 1012,
the diameter of the neck 1019 reduces thereby reducing the amount
of total surface tension holding the drop, so that the momentum of
the drop as it is ejected out of the nozzle is sufficient to allow
the drop to break off.
[0513] When the drop 1016 breaks off, cavitation forces are caused
as reflected by the arrows 1020, as the bubble 1012 collapses to
the point of collapse 1017. It will be noted that there are no
solid surfaces in the vicinity of the point of collapse 1017 on
which the cavitation can have an effect.
[0514] Yet another type of printhead nozzle arrangement suitable
for the present invention will now be described with reference to
FIGS. 52-54. This type typically provides an ink delivery nozzle
arrangement having a nozzle chamber containing ink and a thermal
bend actuator connected to a paddle positioned within the chamber.
The thermal actuator device is actuated so as to eject ink from the
nozzle chamber. The preferred embodiment includes a particular
thermal bend actuator which includes a series of tapered portions
for providing conductive heating of a conductive trace. The
actuator is connected to the paddle via an arm received through a
slotted wall of the nozzle chamber. The actuator arm has a mating
shape so as to mate substantially with the surfaces of the slot in
the nozzle chamber wall.
[0515] Turning initially to FIGS. 52(a)-(c), there is provided
schematic illustrations of the basic operation of a nozzle
arrangement of this embodiment. A nozzle chamber 501 is provided
filled with ink 502 by means of an ink inlet channel 503 which can
be etched through a wafer substrate on which the nozzle chamber 501
rests. The nozzle chamber 501 further includes an ink ejection port
504 around which an ink meniscus forms.
[0516] Inside the nozzle chamber 501 is a paddle type device 507
which is interconnected to an actuator 508 through a slot in the
wall of the nozzle chamber 501. The actuator 508 includes a heater
means e.g. 509 located adjacent to an end portion of a post 510.
The post 510 is fixed to a substrate.
[0517] When it is desired to eject a drop from the nozzle chamber
501, as illustrated in FIG. 52(b), the heater means 509 is heated
so as to undergo thermal expansion. Preferably, the heater means
509 itself or the other portions of the actuator 508 are built from
materials having a high bend efficiency where the bend efficiency
is defined as:
bend efficiency = Young ' s Modulus .times. ( Coefficient of
thermal Expansion ) Density .times. Specific Heat Capacity
##EQU00001##
[0518] A suitable material for the heater elements is a copper
nickel alloy which can be formed so as to bend a glass
material.
[0519] The heater means 509 is ideally located adjacent the end
portion of the post 510 such that the effects of activation are
magnified at the paddle end 507 such that small thermal expansions
near the post 510 result in large movements of the paddle end.
[0520] The heater means 509 and consequential paddle movement
causes a general increase in pressure around the ink meniscus 505
which expands, as illustrated in FIG. 52(b), in a rapid manner. The
heater current is pulsed and ink is ejected out of the port 504 in
addition to flowing in from the ink channel 503.
[0521] Subsequently, the paddle 507 is deactivated to again return
to its quiescent position. The deactivation causes a general reflow
of the ink into the nozzle chamber. The forward momentum of the ink
outside the nozzle rim and the corresponding backflow results in a
general necking and breaking off of the drop 512 which proceeds to
the print media. The collapsed meniscus 505 results in a general
sucking of ink into the nozzle chamber 502 via the ink flow channel
503. In time, the nozzle chamber 501 is refilled such that the
position in FIG. 52(a) is again reached and the nozzle chamber is
subsequently ready for the ejection of another drop of ink.
[0522] FIG. 53 illustrates a side perspective view of the nozzle
arrangement. FIG. 54 illustrates sectional view through an array of
nozzle arrangement of FIG. 53. In these figures, the numbering of
elements previously introduced has been retained.
[0523] Firstly, the actuator 508 includes a series of tapered
actuator units e.g. 515 which comprise an upper glass portion
(amorphous silicon dioxide) 516 formed on top of a titanium nitride
layer 517. Alternatively a copper nickel alloy layer (hereinafter
called cupronickel) can be utilized which will have a higher bend
efficiency.
[0524] The titanium nitride layer 517 is in a tapered form and, as
such, resistive heating takes place near an end portion of the post
510. Adjacent titanium nitride/glass portions 515 are
interconnected at a block portion 519 which also provides a
mechanical structural support for the actuator 508.
[0525] The heater means 509 ideally includes a plurality of the
tapered actuator unit 515 which are elongate and spaced apart such
that, upon heating, the bending force exhibited along the axis of
the actuator 508 is maximized. Slots are defined between adjacent
tapered units 515 and allow for slight differential operation of
each actuator 508 with respect to adjacent actuators 508.
[0526] The block portion 519 is interconnected to an arm 520. The
arm 520 is in turn connected to the paddle 507 inside the nozzle
chamber 501 by means of a slot e.g. 522 formed in the side of the
nozzle chamber 501. The slot 522 is designed generally to mate with
the surfaces of the arm 520 so as to minimize opportunities for the
outflow of ink around the arm 520. The ink is held generally within
the nozzle chamber 501 via surface tension effects around the slot
522.
[0527] When it is desired to actuate the arm 520, a conductive
current is passed through the titanium nitride layer 517 within the
block portion 519 connecting to a lower CMOS layer 506 which
provides the necessary power and control circuitry for the nozzle
arrangement. The conductive current results in heating of the
nitride layer 517 adjacent to the post 510 which results in a
general upward bending of the arm 20 and consequential ejection of
ink out of the nozzle 504. The ejected drop is printed on a page in
the usual manner for an inkjet printer as previously described.
[0528] An array of nozzle arrangements can be formed so as to
create a single printhead. For example, in FIG. 54 there is
illustrated a partly sectioned various array view which comprises
multiple ink ejection nozzle arrangements of FIG. 73 laid out in
interleaved lines so as to form a printhead array. Of course,
different types of arrays can be formulated including full color
arrays etc.
[0529] The construction of the printhead system described can
proceed utilizing standard MEMS techniques through suitable
modification of the steps as set out in U.S. Pat. No. 6,243,113
entitled "Image Creation Method and Apparatus (IJ 41)" to the
present applicant, the contents of which are fully incorporated by
cross reference.
[0530] The integrated circuits 50 may be arranged to have between
5000 to 100,000 of the above described ink delivery nozzles
arranged along its surface, depending upon the length of the
integrated circuits and the desired printing properties required.
For example, for narrow media it may be possible to only require
5000 nozzles arranged along the surface of the printhead assembly
to achieve a desired printing result, whereas for wider media a
minimum of 10,000, 20,000 or 50,000 nozzles may need to be provided
along the length of the printhead assembly to achieve the desired
printing result. For full colour photo quality images on A4 or US
letter sized media at or around 1600 dpi, the integrated circuits
50 may have 13824 nozzles per color. Therefore, in the case where
the printhead assembly 22 is capable of printing in 4 colours (C,
M, Y, K), the integrated circuits 50 may have around 53396 nozzles
disposed along the surface thereof. Further, in a case where the
printhead assembly 22 is capable of printing 6 printing fluids (C,
M, Y, K, IR and a fixative) this may result in 82944 nozzles being
provided on the surface of the integrated circuits 50. In all such
arrangements, the electronics supporting each nozzle is the
same.
[0531] The manner in which the individual ink delivery nozzle
arrangements may be controlled within the printhead assembly 22
will now be described with reference to FIGS. 55-58.
[0532] FIG. 55 shows an overview of the integrated circuit 50 and
its connections to the SoPEC device (discussed above) provided
within the control electronics of the print engine 1. As discussed
above, integrated circuit 50 includes a nozzle core array 901
containing the repeated logic to fire each nozzle, and nozzle
control logic 902 to generate the timing signals to fire the
nozzles. The nozzle control logic 902 receives data from the SoPEC
device via a high-speed link.
[0533] The nozzle control logic 902 is configured to send serial
data to the nozzle array core for printing, via a link 907, which
may be in the form of an electrical connector. Status and other
operational information about the nozzle array core 901 is
communicated back to the nozzle control logic 902 via another link
908, which may be also provided on the electrical connector.
[0534] The nozzle array core 901 is shown in more detail in FIGS.
56 and 57. In FIG. 56, it will be seen that the nozzle array core
901 comprises an array of nozzle columns 911. The array includes a
fire/select shift register 912 and up to 6 color channels, each of
which is represented by a corresponding dot shift register 913.
[0535] As shown in FIG. 57, the fire/select shift register 912
includes forward path fire shift register 930, a reverse path fire
shift register 931 and a select shift register 932. Each dot shift
register 913 includes an odd dot shift register 933 and an even dot
shift register 934. The odd and even dot shift registers 933 and
934 are connected at one end such that data is clocked through the
odd shift register 933 in one direction, then through the even
shift register 934 in the reverse direction. The output of all but
the final even dot shift register is fed to one input of a
multiplexer 935. This input of the multiplexer is selected by a
signal (corescan) during post-production testing. In normal
operation, the corescan signal selects dot data input Dot[x]
supplied to the other input of the multiplexer 935. This causes
Dot[x] for each color to be supplied to the respective dot shift
registers 913.
[0536] A single column N will now be described with reference to
FIG. 77. In the embodiment shown, the column N includes 12 data
values, comprising an odd data value 936 and an even data value 937
for each of the six dot shift registers. Column N also includes an
odd fire value 938 from the forward fire shift register 930 and an
even fire value 939 from the reverse fire shift register 931, which
are supplied as inputs to a multiplexer 940. The output of the
multiplexer 940 is controlled by the select value 941 in the select
shift register 932. When the select value is zero, the odd fire
value is output, and when the select value is one, the even fire
value is output.
[0537] Each of the odd and even data values 936 and 937 is provided
as an input to corresponding odd and even dot latches 942 and 943
respectively.
[0538] Each dot latch and its associated data value form a unit
cell, such as unit cell 944. A unit cell is shown in more detail in
FIG. 58. The dot latch 942 is a D-type flip-flop that accepts the
output of the data value 936, which is held by a D-type flip-flop
944 forming an element of the odd dot shift register 933. The data
input to the flip-flop 944 is provided from the output of a
previous element in the odd dot shift register (unless the element
under consideration is the first element in the shift register, in
which case its input is the Dot[x] value). Data is clocked from the
output of flip-flop 944 into latch 942 upon receipt of a negative
pulse provided on LsyncL.
[0539] The output of latch 942 is provided as one of the inputs to
a three-input AND gate 945. Other inputs to the AND gate 945 are
the Fr signal (from the output of multiplexer 940) and a pulse
profile signal Pr. The firing time of a nozzle is controlled by the
pulse profile signal Pr, and can be, for example, lengthened to
take into account a low voltage condition that arises due to low
power supply (in a removable power supply embodiment). This is to
ensure that a relatively consistent amount of ink is efficiently
ejected from each nozzle as it is fired. In the embodiment
described, the profile signal Pr is the same for each dot shift
register, which provides a balance between complexity, cost and
performance. However, in other embodiments, the Pr signal can be
applied globally (ie, is the same for all nozzles), or can be
individually tailored to each unit cell or even to each nozzle.
[0540] Once the data is loaded into the latch 942, the fire enable
Fr and pulse profile Pr signals are applied to the AND gate 945,
combining to the trigger the nozzle to eject a dot of ink for each
latch 942 that contains a logic 1.
[0541] The signals for each nozzle channel are summarized in the
following table:
TABLE-US-00003 Name Direction Description D Input Input dot pattern
to shift register bit Q Output Output dot pattern from shift
register bit SrClk Input Shift register clock in - d is captured on
rising edge of this clock LsyncL Input Fire enable - needs to be
asserted for nozzle to fire Pr Input Profile - needs to be asserted
for nozzle to fire
[0542] As shown in FIG. 58, the fire signals Fr are routed on a
diagonal, to enable firing of one color in the current column, the
next color in the following column, and so on. This averages the
current demand by spreading it over 6 columns in time-delayed
fashion.
[0543] The dot latches and the latches forming the various shift
registers are fully static in this embodiment, and are CMOS-based.
The design and construction of latches is well known to those
skilled in the art of integrated circuit engineering and design,
and so will not be described in detail in this document.
[0544] The nozzle speed may be as much as 20 kHz for the printer
unit 2 capable of printing at about 60 ppm, and even more for
higher speeds. At this range of nozzle speeds the amount of ink
than can be ejected by the entire printhead assembly 22 is at least
50 million drops per second. However, as the number of nozzles is
increased to provide for higher-speed and higher-quality printing
at least 100 million drops per second, preferably at least 500
million drops per second and more preferably at least 1 billion
drops per second may be delivered. At such speeds, the drops of ink
are ejected by the nozzles with a maximum drop ejection energy of
about 250 nanojoules per drop.
[0545] Consequently, in order to accommodate printing at these
speeds, the control electronics must be able to determine whether a
nozzle is to eject a drop of ink at an equivalent rate. In this
regard, in some instances the control electronics must be able to
determine whether a nozzle ejects a drop of ink at a rate of at
least 50 million determinations per second. This may increase to at
least 100 million determinations per second or at least 500 million
determinations per second, and in many cases at least 1 billion
determinations per second for the higher-speed, higher-quality
printing applications.
[0546] For the printer unit 2 of the present invention, the
above-described ranges of the number of nozzles provided on the
printhead assembly 22 together with the nozzle firing speeds and
print speeds results in an area print speed of at least 50 cm.sup.2
per second, and depending on the printing speed, at least 100
cm.sup.2 per second, preferably at least 200 cm.sup.2 per second,
and more preferably at least 500 cm.sup.2 per second at the
higher-speeds. Such an arrangement provides a printer unit 2 that
is capable of printing an area of media at speeds not previously
attainable with conventional printer units.
Lid Assembly
[0547] The lid assembly 21 of the cartridge unit 10 is shown in
FIGS. 59-61. The lid assembly 21 is arranged to fit over the main
body 20, thereby sealing each of the ink storage compartments 24.
As such, the lid assembly 21 is shaped to conform to the shape of
main body 20 and is attached to the main body via ultrasonic
welding, or any other suitable method which provides a sealed
connection.
[0548] The outer surface 60 of the lid assembly 21 is provided with
a number of ink refill ports 61, for receiving ink from a refill
unit 200 and for directing the refill ink into one of the ink
storage compartments 24 of the main body 20. In the embodiment
shown in FIG. 59, there are five ink refill ports 61 provided, with
each of the refill ports being in fluid communication with one of
the five ink storage compartments 24 to facilitate refilling of the
associated compartments with ink.
[0549] The ink refills ports 61 are in the form of holes extending
through the lid assembly 11 and each hole is provided with a valve
fitting 62 made from an elastomeric moulding. The valve fittings 62
act to seal the ports 61 during non refill periods and provide a
means for interacting with an outlet of the ink refill unit 200 to
ensure controlled transfer of ink between the ink refill unit 200
and the ink storage compartment 24. In this regard, when an ink
refill unit 200 is not in communication with the ink refill ports
61 the valve fittings 62 seal the ink refill ports, and when the
ink refill unit 200 is in communication with the ink refill ports,
the valve fittings permits transfer of ink from the ink refill unit
through the ink refill ports. The manner in which this is achieved
is described later in the description.
[0550] The outer surface 60 of the lid assembly 21 also includes a
venting arrangement which provides air venting of each ink storage
compartment 24. The venting arrangement consists of individual vent
holes 63 which extend into the individual ink storage compartments
24 and channels 64 which extend from the vent holes 63 to the edge
of the lid assembly 21. The channels 64 are preferably etched into
the outer surface 60 of the lid assembly and assume a tortuous path
in the passage from the vent holes 63 to the edge of the lid
assembly.
[0551] As shown in FIG. 61, a film 65 is placed over the outer
surface 60 of the lid assembly and includes holes 66 formed therein
which fit around the ink refill ports 61. The film 65 may be an
adhesive film such as a sticker/label or the like which may also
have printed thereon instruction information to assist the user in
handling the cartridge unit 10. When applied to the surface of the
lid assembly 21, the film sits atop the etched channels 64 formed
in the outer surface 60, thereby enclosing the venting passage from
the vent hole 63 to the edge of the lid assembly 21 which enables
the ink storage compartment to breathe via the tortuous path.
[0552] The underside of the lid assembly 21 is shown in more detail
in FIG. 60 and includes flow channels 67 extending from the
underside of the ink refill ports 61 to direct the refill ink into
the appropriate ink storage compartment 24. As shown in FIG. 61, a
weld membrane 68 is welded to the underside of the ink refill ports
61 and the flow channels 67 to form sealed delivery passages along
which the ink passes en route to each of the ink storage
compartments 24.
[0553] The underside of the lid assembly 21, also includes moulded
features or ridges 69 which extend into the ink storage
compartments 24 when the lid assembly 21 is sealed to the main body
20. These moulded features or ridges 69 ensure that an air gap is
formed above the absorbent material 29 for venting via the vent
hole 63 to assist the absorbent material 29 to function to absorb
the ink and retain the ink suspended therein under capillary
action.
[0554] As shown in FIGS. 59 and 60, extending downwardly from the
outer surface 60 of the lid assembly 21 are a pair of guide walls
70. The guide walls 70 assist in locating the lid assembly 21 on
the main body 20 during assembly. The guide walls 70 also have a
recessed portion 71 formed therein which acts as a hand grip to
assist in handling the cartridge unit during use.
[0555] As shown more clearly in FIG. 59, the guide wall 70 that
extends along the face of the main body 20 proximal the printhead
assembly 22 also includes a series of holes 72 in a lower edge
thereof. These holes 72 are arranged to align with and receive the
locating studs 38 provided on the main body 20 onto which the flex
PCB backer 37 and the flex PCB 52 of the printhead assembly 22 are
attached. In this arrangement, when the lid assembly 21 is fixed to
the main body 20, a portion of the flex PCB 52 of the printhead
assembly 22 is sandwiched between the guide wall 70 and the flex
PCB backer 37, thereby acting to help retain the flex PCB 52 in
position.
Capper Assembly
[0556] As discussed previously and shown in FIGS. 11 and 12, the
main body 20 of the cartridge unit 10 is provided with downwardly
projecting end supports 40. The end supports 40 are integral with
the main body 20 and are arranged such that the printhead assembly
22 is positioned between the end supports. Each of the end supports
40 are configured to receive the capping assembly 23 and as such
have retaining projections 73 formed on their surfaces to retain
the capping assembly 23 in position.
[0557] The capping assembly 23 is shown in more detail in FIGS. 62
to 67, and generally consists of a capper chassis 74 which receives
the various components of the capping assembly 23 therein. The
capper chassis 74 is in the form of an open ended channel having a
pair of upwardly extending tongue portions 75 at its ends which are
shaped to fit over the end supports 40 of the main body and engage
with the retaining projections 73 provided thereon to secure the
capper assembly 23 in position. The capper chassis 74 essentially
retains the parts of the capper assembly 23 therein, and is made
from a suitable metal material, having rigidity and resilience,
such as a pressed steel plate.
[0558] The base of the capper chassis 74 is shown more clearly in
FIG. 64 and includes a centrally located removed portion 76 and
spring arms 77 extending from either side of the removed portion 76
towards the tongue portions 75. The spring arms 77 are hingedly
fixed to the chassis 74 at the region proximal the removed portion,
and are biased inwards of the capper chassis. The spring arms 77
may be made from the same material as the chassis and formed by
removing material from the chassis pressing the arms from the base
of the chassis. Whilst the spring arms 77 are shown as being
integral with the chassis 74, they may be provided as a separate
insert which may be inserted into the open channel of the chassis
74, as would be appreciated by a person skilled in the art.
[0559] A rigid insert 78 is provided to fit within the chassis 74
to provide added rigidity to the capper assembly 23. In this regard
the insert 78 is made from moulded steel and forms an open u-shaped
channel. A lower capper moulding 79 is located within the insert 78
and retained within the insert via engagement of a number of lugs
80 formed along the sides of the lower capper moulding 79 with
corresponding holes 81 provided in the sides of the insert 78. The
lower capper moulding 79 is made from a suitable plastic material
and forms a body having closed ends and an open top. The ends of
the lower capper moulding 79 are provided with air vents 82 which
provide a means for air to enter the capper assembly and ventilate
the capper assembly.
[0560] The base of the lower capper moulding is provided with a
pair of centrally located projections 83 which are received within
slots 84 formed in the base of the rigid insert 78. The projections
83 extend through the rigid insert 78, beyond its outer base
surface to define a region for receiving an electromagnetic button
85, which is spot welded to the outer base surface of the rigid
insert 78 between the projections 83. The purpose of the
electromagnetic button 85 will be discussed in more detail later in
the description; however it should be appreciated that the
electromagnetic button 85 can be made of any material which is
capable of experiencing magnetic attraction forces.
[0561] A strip of absorbent media 86 is provided to fit within the
lower capping moulding 79, and may be made from any type of
material capable of absorbing and retaining ink therein, such as
urethane foam or the like. The absorbent media 86 is shaped to fit
within the lower capper moulding 79 and includes a stepped portion
87 which projects above the lower capper moulding 79 and extends
centrally along the length of the absorbent media 86, as is shown
more clearly with regard to FIGS. 63 and 65.
[0562] An upper capper moulding 88 is then provided to fit over the
lower capper moulding 79 and the absorbent media 86. The upper
capper moulding 88 has essentially two portions, a lower portion 89
which seals along the edges of the lower capper moulding 79 to
retain the absorbent media 86 therein, and an upper portion 90
which essentially conforms to the shape of the stepped portion 87
of the absorbent media 86. The lower portion 89 is made from a
rubber or plastics material and has an edge portion which sits
along the upper edge of the lower capping moulding 79 and which is
attached thereto by an ultrasonic weld or any other suitable
attachment means. The upper portion 90 has an open upper surface
and is made from a dual shot elastomeric material. The open upper
surface is in the form of a rim portion 91 that extends beyond the
absorbent media 86 and defines a perimeter seal for sealing the
integrated circuits 50 of the printhead assembly 22, as is shown in
relation to FIG. 65. The space formed between the upper edge of the
rim portion 91 and the absorbent media 86 is the space which seals
the integrated circuits 50 of the printhead assembly 22.
[0563] In this arrangement, the upper capper moulding 88, absorbent
media 86, lower capper moulding 79 and the rigid insert 78 form a
unit which is adapted to fit within the capper chassis 74. In order
to secure the unit in place, a retainer element 92 is provided
which fits over the upper capping moulding 88 and is secured to the
chassis 74 as shown in FIG. 62.
[0564] The retainer element 92 is essentially in the form of an
open ended channel which fits over the upper capper moulding 88 and
encloses the components therein. A slot 93 is formed in the upper
surface of the retainer element 92 through which the upper portion
90 of the upper capper moulding 88 can protrude and the slot is
shaped to conform to the shape of the upper portion 90 of the upper
capper moulding 88, as is shown in FIG. 65. The upper surface of
the retainer element 92 is curved and acts as a media guide during
printing, as will be described in more detail later. The retainer
element 92 is fixed to the chassis via a snap-fit arrangement
whereby lugs 94 formed in the retainer element 92 are received in
recesses 95 provided in the chassis 74. When assembled in this
manner, the components of the capper assembly 23 are contained
within the retainer element 92 and the chassis 74, and the
electromagnetic button 85 secured to the rigid insert 78 is aligned
with the centrally located removed portion 76 of the chassis.
[0565] Upon assembly and attachment of the capper assembly 23 to
the end supports 40 of the main body 20, due to the presence of the
spring arms 77 extending inwardly from the base of the chassis 74,
the rigid insert 78 which contains the lower capper moulding 79,
absorbent media 86 and the upper capper moulding 88 therein, is
supported on the spring arms 77 and is raised from the base of the
chassis 74. This state is shown in FIGS. 62 and 65, and in this
state the upper portion 90 of the upper capper moulding 88
protrudes through the slot 93 provided in the retainer element 92.
This state is the capping state, whereby the upper rim portion 91
of the upper capper moulding 88 contacts the printhead assembly 22
and acts as a perimeter seal around the printhead integrated
circuits 50, sealing them within the confined space of the capper
assembly 23. In the capping state, the nozzles 51 of the printhead
integrated circuits 50 may fire and spit ink into the absorbent
material 86. The absorbent material 86, is typically retained in a
moist state at all times, such that when the integrated circuits
are in the capping state, the nozzles are sealed in a moist
environment which prevents ink from drying in the nozzles of the
integrated circuits and blocking the nozzles.
[0566] In order to perform printing, the capper assembly 23 must be
moved from a capping state to a printing state. This is achieved by
causing the rigid insert 78 to act against the spring arms 77 of
the chassis 74 and move in a downwards direction, towards the base
of the chassis 74. This movement is caused by applying an
electromagnetic force in the vicinity of the base of the capper
assembly 23, proximal the centrally located removed portion 76. The
activation of the electromagnet force attracts the electromagnet
button 85 fixed to the underside of the rigid insert 78, thereby
causing the rigid insert, which contains the lower capper moulding
79, absorbent media 86 and the upper capper moulding 88 therein, to
move in a downward direction with respect to the printhead assembly
22. The centrally located removed portion 76 of the base of the
chassis 74 allows the electromagnet button 85 to be fully retracted
against the spring arms 77 towards the source of the
electromagnetic force. This in turn causes the upper rim portion 91
of the upper capping moulding 88 to retract into the retainer
element 92 such that it is flush with the outer surface of the
retainer element 92 and does not protrude therefrom. It will be
appreciated that the retainer element 92 does not move and is fixed
in position. Such a state is referred to as the printing state, and
in this state there is a gap formed between the retainer element 92
and the printhead assembly 22 through which the media can pass for
printing. In the printing state, the retainer element 92 acts as a
media guide and the media contacts the retainer element and is
supported on the surface of the retainer element as it passes the
printhead assembly for printing.
[0567] FIGS. 66 and 67 show the cartridge unit 10 in the capping
state and the printing state respectively. It will be appreciated
that due to the action of the spring arms 77, the capping state is
the relaxed state of the capper assembly 23 and whenever printing
is not occurring the cartridge unit 10 is in the capping state. In
this regard, the cartridge unit 10 is packaged and shipped in the
capping state. As such, to move the cartridge unit 10 into a
printing state, power must be supplied to an electromagnet, which
is located in the cradle unit 12 as described later, to cause the
upper capper moulding 88 to retract into the retainer element 92.
In the event of power failure or cessation of power to the printer
unit, the electromagnetic force is removed, and the capper assembly
23 returns to the capping state under action of the spring arms 77,
thereby protecting the printhead integrated circuits 50 against
prolonged periods of exposure to drying air.
Cradle Unit
[0568] The cradle unit 12 is shown in relation to FIGS. 6-8 and
generally consists of a main body 13 which defines an opening for
receiving the cartridge unit 10, and a cover assembly 11 adapted to
close the opening to secure the cartridge unit 10 in place within
the cradle unit 12.
[0569] The main body 13 of the cradle unit 12 includes a frame
structure 101 as shown in FIGS. 68a-68d. The frame structure 101
generally comprises two end plates 102 and a base plate 103
connecting each of the end plates 102. As mentioned previously,
each of the end plates 102 is provided with anchor portions 14
formed the base thereof to enable the print engine 1 to be secured
in position within the printer unit 2. A drive roller 104 and an
exit roller 105 are mounted between the end plates 102 via mounting
bearings 106 and are separated a distance to accommodate the
cartridge unit 10 when the print engine 1 is fully assembled. The
drive roller 104 and the exit roller 105 are each driven by a
brushless DC motor 107 which is mounted to one of the end plates
102 and drives each of the drive and exit rollers via a drive
mechanism 108, such as a drive belt. Such a system ensures that
both the drive roller 104 and the exit roller 105 are driven at the
same speed to ensure a smooth and consistent passage of the media
through the print engine 1.
[0570] An electromagnet assembly 109 is mounted to the underside of
the base plate 103 in a central position as shown most clearly in
FIGS. 68c and 68d. The purpose of the electromagnet assembly 109 is
to actuate the capper assembly 23 of the cartridge unit 10, as
previously discussed. A hole 110 is provided in the base plate 103
around the electromagnet assembly 109 to facilitate communication
with the electromagnet button 85 on the capper assembly 23.
[0571] A refill solenoid assembly 111 is mounted to the other end
plate 102, opposite the DC motor 107, and is provided to operate a
refill unit 200 to refill the cartridge unit 10 with refill ink, as
will be described later. The refill solenoid assembly 111 is
positioned such that an actuator arm 112 extends beyond the upper
edge of the end plate 102, the purpose of which will become
apparent later in the description.
[0572] Cartridge unit guides 113 are also mounted to the interior
surfaces of each of the end plates 102. The guides are located at
the rear of the cradle unit 12 and assist in positioning the
cartridge unit 10 within the cradle unit 12 to ensure that removal
and replacement of the cartridge unit 10 is a simple process. To
further accommodate the cartridge unit 10, a cartridge unit support
member 114 is mounted between the end plates 102 at the front of
the cradle unit 12. The cartridge unit support member 114 is shown
in more detail in FIG. 69, and is in the form of a shaped plate
fixed to the front portion of the cradle unit 12. The cartridge
unit support member 114 has a pair of clips 115 which fit into
recesses 116 formed in the end plates 102 and has further anchor
points 117 which enable the cartridge unit support member to be
fixed to the end plates 102, via screws or the like, to form a
surface upon which the cartridge unit 10 can be received and
supported. The cartridge unit support member 114 together with the
cartridge unit guides 113, defines a space 118 for receiving the
cartridge unit 10 therein which conforms to the shape of the
cartridge unit 10, as shown in FIG. 70.
[0573] An idle roller assembly 119 is fixed to the cartridge unit
support member 114 and includes a plurality of roller wheels 120
which are positioned to contact the surface of the drive roller 104
and rotate therewith. The idle roller assembly 119 is shown in
FIGS. 71a and 71b and comprises a curved multi-sectioned plate 121
with each section of the plate having a pair of roller wheels 120
provided at its distal end. Each section of the plate 121 is spring
loaded against the surface of the cartridge unit support member 114
via a suitable spring means 122, to allow the roller wheels 120 to
move with respect to the surface of the drive roller 104 to
accommodate print media therebetween. The idle roller assembly 119
is attached to the under-surface of the cartridge unit support
member 114 via clips 123 which are received in corresponding slots
124 formed in the cartridge unit support member 114, as is shown in
FIG. 72. Such an arrangement ensures that the media that is
presented to the print engine 1 from the picker mechanism 9 of the
printer unit 2, is gripped between the drive roller 104 and the
idle roller assembly 119 for transport past the printhead assembly
22 of the cartridge unit 10 for printing.
[0574] The control electronics for the print engine which controls
the operation of the integrated circuits 50 of the printhead
assembly 22, as well as the operation of the drive roller 104 and
exit roller 105 and other related componentry, is provided on a
printed circuit board (PCB) 125 as shown in FIGS. 73a and 73b. As
can be seen, one face of the PCB 125 contains the SoPEC devices 126
and related componentry 127 for receiving and distributing the data
and power received, as will be discussed later, whilst the other
face of the PCB includes rows of electrical contacts 128 along an
edge thereof which provides a means for transmitting the power and
data signals to the printhead assembly 22 in a manner to be
described below.
[0575] The PCB 125 is mounted between two arms 129, with each of
the arms having a claw portion 130 to receive the PCB 125 in
position, as shown in FIGS. 74a-74c. Each arm 129 is configured to
have a substantially straight edge 131 and an angled edge 132
having a protrusion 133 formed thereon. The PCB 125 is positioned
between the arms 129 such that the face of the PCB having the
electrical contacts 128 formed along the lower edge thereof extends
between the substantially straight edges 131 of the arms 129.
[0576] The upper region of each of the arms 129 includes an
upwardly extending finger portion 134 and a spring element 135 is
provided for each of the arms 129, the purpose of the finger
portion 134 and the spring element 135 will be discussed in more
detail later.
[0577] In order to provide stability to the PCB 125 as it is
mounted between the two arms 129, a support bar 136 is attached to
the assembly which acts along the bottom edge of the PCB 125, on
the face that contains the SoPEC devices 126 and the related
componentry 127. This support bar 136 is shown in FIGS. 75a-75b and
consists of a curved plate 137 made from a suitable material such
as steel which has appropriate strength and rigidity properties.
The support bar 136 has a contact edge 138 which is arranged to
contact the surface of the PCB 125, along its bottom edge opposite
the electrical contacts 128. The contact edge 138 has a pair of
attachment points 139 at its ends which allow the support bar 136
to be secured to the PCB 125 via screws or other suitable
attachment means. Locating projections 140, are also provided to
mate with appropriate locating holes in the PCB 125 to assist in
correctly position the support bar 136 in place. The contact edge
138 includes an electrical insulator coating 141 along its length
which performs the contact between the support bar 136 and the PCB
125. It will be appreciated that the support bar 136 contacts the
surface of the PCB 125 along its' lower edge and provides backing
support to the electrical contacts 128 when they come into contact
with the corresponding dimple contacts 53 provided on the flex PCB
52 of the printhead assembly 22.
[0578] The support bar 136 also includes a relatively straight
portion 142 which extends substantially horizontally from the
contact edge 138. The straight portion 142 includes a pair of tabs
143 that extend longitudinally from its ends to engage with
corresponding slots 144 provided in the arms 129 to further secure
the support bar 136 in position. A plurality of star wheels 145 is
also provided along the length of the straight portion 142 in a
staggered arrangement. The star wheels 145 are secured within slots
146 formed in the straight portion 142 and are provide on spring
loaded axles 147 which permits relative movement of the star wheels
145 with respect to the straight portion of the support bar 146.
The star wheels 145 are provided to contact the surface of the exit
roller 105 to assist in gripping and removing the printed media
from the print engine 1, as will be discussed below. FIG. 76 shows
the support bar 136 attached to the PCB 125 and arms 129.
[0579] The arms 129 are attached to a bottom portion of end plates
102 at the pivot point 148 via a screw arrangement as shown in
FIGS. 77a and 77b. In this arrangement the arms 129, and
subsequently the PCB 125 and support bar 136, is able to pivot
about the pivot point 148 between an open position wherein the
contacts 128 on the PCB 125 are remote from the dimpled contacts 53
on the flex PCB 52 of the cartridge unit 22, and a closed position
where the contacts 128 on the PCB 125 are in pressing contact with
the dimpled contacts 53 on the flex PCB 52 of the cartridge unit
22. As clearly shown, upon attachment of the arms 129 to the end
plates 102, the star wheels 145 are in contact with the surface of
the exit roller 105, to capture the sheet of media therebetween for
removal of the sheet from the print engine 1 to a collection area 4
for collection.
[0580] The cover assembly 11, as shown in FIGS. 78a-78c, is
attached to the upper portion of the end plates 102 via pivot pins
150 which are received in holes 151 formed in the upper portion of
the end plates 102. The cover assembly 11 is made from a moulded
plastic material and the pivot pins 150 are formed proximal to a
rear edge of the cover assembly 11 during the moulding process. The
pivot pins 150 allow the cover assembly 11 to pivot about the end
plates 102 between a closed position, where the cartridge unit 10
is secured within the cradle unit 12, and an open position, where
the cartridge unit 10 can be removed from the cradle unit 12 and
replaced. A latch 152 is provided in a front edge 153 of the cover
assembly 11. The latch 152, has a flexible clip element 154 which
is received within a recess 155 provided in the cartridge unit
support member 114 when the cover assembly 11 is in the closed
position, as shown in FIG. 81. The flexible clip element 154 is
spring loaded via a spring element (not shown) such that the clip
element 154 can be readily depressed to release engagement between
it and the recess 155 provided in the cartridge unit support member
114 so that the cover assembly 11 can be pivoted into an open
position, as shown in FIG. 80.
[0581] Positioned adjacent the pivot pins 150, on the inside of the
cover assembly 11, are a pair of posts 156. The posts 156 are
arranged substantially alongside the pivot pins 150, towards the
front edge 153 of the cover assembly 11. The posts 156 are
configured such that they are a greater length than the pivot pins
150 and hence extend inwardly a greater distance, to contact the
spring element 135 of the arms 129 which support the PCB 125.
[0582] In this regard, the act of opening and closing the cover
assembly 11 also performs the function of bringing the contacts 128
provided on the surface of the PCB 125, into contact with the
corresponding dimpled contacts 53 provided on the flex PCB 52 of
the printhead assembly 22. To achieve this, the cover assembly 11
and the arms 129 are arranged as shown in FIG. 79.
[0583] As shown, the cover assembly 11 is attached to the end
plates 102 such that the posts 156 extend between the upwardly
extending finger portion 134 and the spring element 135 at each end
thereof. When the cover assembly 11 is moved to the open position,
as shown in FIG. 80, the posts 156 act against the upwardly
extending finger portion 134 of the arms 129 causing the arms 129,
and the PCB 125, to pivot away from contact with the dimpled
contacts 53 of the flex PCB 52 of the cartridge unit 22. This
movement is due to the swing action of the cover assembly 11 when
opened which in turn causes the posts 156 to move in an arcuate
direction towards the rear of the print engine 1. When the cover
assembly 11 moves to the closed position as shown in FIG. 81, the
cover assembly 11 pivots about the pivot pins 150, causing the
posts 156 to move in an arcuate direction towards the front of the
print engine 1. As the posts 156 move, they contact the upright
portion of the spring element 135, causing the PCB 125 and the arms
129 to pivot forward. The spring element 135 has considerable
rigidity to transfer the force exerted upon it by the posts 156
into forward movement of the PCB 125 and arms 129 which results in
the contacts 128 on the outward lower portion of the PCB 125 to
contact the corresponding dimpled contacts 53 provided on the flex
PCB 52 of the cartridge unit 10, which is positioned and supported
on the flex PCB backer 37. As the cover assembly 11 is secured in
place by the clip element 154 gripping the recessed portion 155 of
the cartridge unit support member 114, the contacts 128 remain in
aligned contact with the dimpled contacts 53, ensuring that power
and data can be transmitted between the SoPEC devices 126 and the
integrated circuits 50 of the printhead assembly 22. Due to the
fact that the posts 156 act against the upright portion of the
spring element 135, with the corresponding horizontal portion of
the spring element 135 being secured against the arms 129, there is
a return force stored in the spring element 135 such that when the
latch 152 of the cover assembly 11 is released the PCB 125 and the
arms 129 will begin to pivot away from contact with the dimpled
contacts 53 of the flex PCB 52, breaking electrical contact
therebetween and allowing ready removal of the cartridge unit
10.
[0584] As shown in FIGS. 78a-78c, the cover assembly 11 includes a
centrally located docking port 157 in the form of a hole formed
through the cover assembly 11. The docking port 157 is shaped to
enable a refill unit 200 to pass therethrough to dock with the
cartridge unit 10 thereby enabling refilling of the cartridge unit
10 with ink, in a manner which will be described below. The docking
port 157 has a rim portion 158 upon which a portion of the base of
the refill unit 200 is received. Formed within the rim portion 158
of the docking port 157 is an engagement means 159 which engages
with the refill unit 200 to retain the refill unit securely in
position to facilitate refilling of the cartridge unit 12. A QA
chip reader 160 is also formed in the rim 158 of the docking port
157 to mate with a corresponding QA chip provided in the refill
unit 200 to ensure integrity of the refill unit. The manner in
which the engagement means 159 and the QA chip reader 160 functions
will be described in more detail later in the description.
[0585] Projecting into the docking port 157 via a hole 161 formed
in the wall of the rim portion 158, as shown in FIG. 78c, is a push
rod 162. As shown more clearly in FIG. 82, the push rod 162 is in
the form of an elongate bar member having an end 163 of reduced
cross section which extends through the hole 161 in the wall of the
rim portion 158; and an end having a foot portion 164, a part of
which extends perpendicular to the length of the push rod 162. The
body of the push rod 162, proximal the foot portion 164, has a slot
165 formed therein which enables the push rod 162 to be secured to
the underside of the cover assembly 11 by way of a screw or the
like upon which a push clip 166 is secured. The push clip 166
allows the push rod 162 to move longitudinally with respect to the
push clip 166 but prevents any sideways or downward movement of the
push rod 162. A retainer 167 is also provided in the underside of
the cover assembly 11 proximal the docking port 157 to retain the
push rod in position and to prevent any non-longitudinal movement
of the push rod 162. In this configuration, the pushrod 162 is free
to move in a longitudinal direction with respect to its length,
such that the end 163 of reduced cross section can enter and be
withdrawn from the docking port 157. A spring element 168 is
provided in the slot 165 formed in the push rod 162 and acts to
bias the push rod 162 into position, such that its natural position
is to have its end 163 extend into the docking port 157.
[0586] The foot portion 164 of the push rod 162 is shown in more
detail in FIG. 83. The part of the foot portion 164 which extends
perpendicular to the length of the push rod, has a groove 169
formed therein. The surface 170 of the groove is angled towards the
end 163 of the push rod, as shown. The foot portion 164 is
positioned at the side edge of the cover assembly 11 and extends in
a downward direction with respect to the cover assembly 11. In this
position the actuator arm 112 of the refill solenoid assembly 111
mounted on the cradle unit 12 is orientated such that it is aligned
with the groove 169 of the foot portion 164. As the actuator arm
112 is raised by the solenoid assembly 111 in a vertical direction,
it travels along the surface 170 of the groove 169 thereby causing
the push rod 162 to retract such that the end 163 of the push rod
162 no longer extends into the docking port 157. Lowering of the
actuator arm 112 by the solenoid assembly 111 results in the push
rod 162 returning to its naturally biased position under the action
of the spring element 168, whereby the end 163 extends into the
docking port 157. The manner in which the end 163 of the push rod
interacts with the refill assembly 200 will be discussed in more
detail below, however it should be appreciated that the position of
the push rod is controlled by the SoPEC device 126 with regard to
the state of operation of the printer unit.
Refill Unit
[0587] FIG. 47 illustrates one embodiment of an ink refill unit
200. The ink refill unit 200 generally comprises a base assembly
202 which houses internal ink refilling components and a lid
assembly 204 which fits onto the base assembly 202. The base and
lid assemblies may be moulded from a plastics material and the base
assembly may be moulded as a single piece or in sections (as shown
in FIG. 88).
[0588] As mentioned previously, the refill unit 200 contains ink
and is intended to be used as a means for refilling the ink storage
compartments 24 within the cartridge unit 10. The refill unit 200
is configured to dock with the surface of the cartridge unit 10 in
order to transfer the ink it contains into the ink storage
compartments 24 of the cartridge unit 10. For this purpose, the
cover assembly 11 of the cradle unit 12 has a docking port 157
formed therein through which the refill unit 200 is able to pass to
dock with the upper surface of the print cartridge 10.
[0589] As discussed previously in relation to the lid assembly 21
of the cartridge unit 10, the upper surface 60 of the lid assembly
21 has a plurality of ink refill ports 61 formed therein, with each
of the individual ink refill ports 61 being in fluid communication
with one of the ink storage compartments 24 to deliver ink to that
compartment. The position of the individual ink refill ports 61 on
the surface of the cartridge unit 10 is specific to the type or
colour of ink stored by the cartridge unit, and the position and
configuration of the ink refill ports 61 is consistent between
different cartridge units. In this regard, each refill unit 200 is
configured with a plurality of outlets 206 located in a bottom
section 202a of the base assembly 202 for docking with the
cartridge unit. However in each instance, only one of the outlets
is in fluid communication with the supply of ink for distributing
ink to an ink storage compartment of the cartridge unit through the
corresponding ink refill port, the position of the outlet being
dependant upon the type or colour of ink to be supplied from the
refill unit. As shown in FIG. 88, the refill unit 200 is arranged
with one working outlet 208 for the distribution of the particular
coloured ink contained in the refill unit to the ink refill port 61
of the correspondingly coloured ink storage compartment 24 in the
cartridge unit 10. That is, if the refill unit 200 contains cyan
ink, the working outlet 208 is positioned so as to correspond to
the ink refill port 61 of the cyan ink chamber of the cartridge
unit 10 when the refill unit is docked with the cartridge unit.
[0590] A clip arrangement 210 is provided on at least one side of
the base assembly 202 of the refill unit 200 for securing the
refill unit to the print engine during the refilling operation.
This ensures reliable and efficient transfer of ink from the refill
unit 200 to the cartridge unit as the refill unit 200 is
substantially immovable from the print engine until the clip
arrangement 210 is disengaged, thereby ensuring a complete seal
between the refill unit and the cartridge unit and preventing the
possibility of ink spillage or air ingress between the outlet and
the ink refill port.
[0591] In this regard, the clip arrangement 210 is formed as a
resilient section of the side wall of the base assembly 202 and is
movable with respect the remainder of the side wall so as to engage
and disengage with a corresponding engagement means 159 provided in
the docking port 157 of the cover assembly 11 of the cradle unit.
The clip arrangement includes clip portions 212 in the form of
projections that project from a resilient arm 214, the arm 214
being depressible to move into and out of a recess 216 about a
pivot region 218, the pivot region 218 being a weakened region in
the surface of the base assembly 202. In this way, when the bottom
section 202a of the base assembly 202 is moved into docking
engagement with the surface of the cartridge unit by being passed
through the docking port 157 of the cover assembly, the engagement
means 159 of the cover assembly comes into contact with the clip
portions 212. This contact causes the arm 214 to deflect into the
recess 216 as the refill unit is pushed into docking position with
the cartridge unit, until the clip portions pass the engagement
means 159 of the cover assembly. At this point, the arm 214 is no
longer in contact with the engagement means 159 and hence returns
to its original position thereby engaging the clip portions 212
with the lip of the engagement means 159.
[0592] The clip and engagement means of the refill unit and the
cover assembly, respectively, are configured so that in the docked
(refilling) position, the outlets 206, and most importantly the
working outlet 208, of the refill unit 200 is snugly positioned on
the refill ports of the cartridge unit.
[0593] Once refilling has been completed, the refill unit 200 can
be removed from docking engagement with the cartridge unit, by
depressing the resilient arm 214 such that the clip portions 212
disengage with the lip of the engagement means. Suitable detail
ridges 222 may be provided on the resilient arm 214 to provide grip
for a user's finger(s) to manipulate the clip arrangement 210.
[0594] The clip arrangement 210 and corresponding engagement
portion 110 may be provided on only one side of the refill unit 200
and cover assembly, or may be provided on both (opposite)
sides.
[0595] Within the refill unit 200 the ink is stored in a
syringe-type assembly 224. The syringe-type assembly 224 is mounted
within the base assembly 202 of the refill unit 200 so as to be
covered by the lid assembly 204. The syringe-type assembly 224 has
the necessary capacity to store the amount of ink required for
refilling of the ink storage compartments of the cartridge unit.
The components of the syringe assembly 224 are most clearly seen in
FIG. 90.
[0596] A tank 226 is provided in the syringe assembly 224 for
storing the ink within the refill unit 200. The tank 226 has at one
end an ejection port 228 through which the ink is ejected for
distribution and is sealed at the other end by a syringe seal 230.
The syringe seal 230 is mounted on a plunger 232 which is received
within the hollow internal space of the tank 226 to expel the
stored ink from the ejection port 228. The plunger 232 is arranged
to be driven into the hollow internal space of the tank 226 under
action of a compression spring 234. The compression spring is
provided within the plunger 232 and projects from the plunger to
contact with the internal end wall of the base assembly 202 (i.e.,
opposite the internal end wall adjacent the ejection port 228 of
the tank 226). In this way, the compression spring 234 applies a
constant force to the plunger 232 urging it plunge towards the
interior of the tank 226 when the syringe assembly 224 is housed in
the base assembly 202.
[0597] Control of the plunging operation, and hence control of the
delivery of the ink from the refill unit, is provided by ratchet
arrangement of the syringe assembly 224. The ratchet arrangement
comprises an actuator rod 236 which mounts at its upper end and an
intermediate position towards its lower end to mounting slots 238
provided on the tank 226. The rod 236 has a pawl 240 projecting
from one side thereof between the positions mounted through the
slots 238. The pawl 240 is engageable with a series of grooves
providing a ratchet 242 on a side surface of the plunger 232.
[0598] The rod 236 is rotatable about its long axis so as to engage
and disengage the pawl 240 with the ratchet 242. An actuator spring
244 is provided at the upper end of the rod 236 which acts against
the side surface of the plunger 232 so as to bias the pawl 240 into
the ratchet 242. The engagement of the pawl 240 and the ratchet 242
provides sufficient resistance against the plunging of the plunger
232 into the interior of the tank 226 under action of the
compression spring 234.
[0599] Thus, upon initial use of the refill unit 200, the pawl 240
is engaged with the first groove of the ratchet 242, thereby
preventing the plunger from substantially entering the interior of
the tank 226 and in turn providing maximum ink storage capacity
within the tank 226. In order to commence refilling of the
cartridge unit, ink must be ejected from the tank 226 through the
ejection port 228. This is achieved through rotation of the rod 236
which disengages the pawl from the first groove. The plunger 232
then enters into the interior of the tank 226 under action of the
compression spring, causing ink to be ejected out the ejection port
228. The pawl 240, following disengagement with the first groove,
engages with the next groove of the ratchet 242 through the return
action of the actuator spring 244 against the initial rotation the
rod 236. This causes movement of the plunger 232 within the
interior of the tank 226 to stop, thereby stopping delivery of ink
from the ejection port 228. More ink can be ejected from the tank
226 by repeated rotation of the rod 236 and
engagement/disengagement of the pawl 240 with the ratchet 242,
thereby providing incremental delivery of ink in controlled
amounts. This continues until the pawl engages with the final
groove of the ratchet, at which point the ink within the tank 226
has been depleted.
[0600] The rotation of the rod 236 to disengage the pawl 240 is
caused by action of an actuator shaft 246 on an arm 248 which
projects from the rod. The actuator shaft 246 is housed within the
base assembly 202, as shown in FIG. 93, so as to be slidable along
its long axis. One end of the actuator shaft 246 is slidable to
contact the arm 248 of the rod 236 when the syringe assembly 224 is
mounted into the base assembly 202 and the other end of the
actuator shaft is slidable to be exposed to the outside of the base
assembly through a hole 202b formed in one of its end walls.
[0601] In order to performing the refilling operation, the exposed
end of the actuator shaft 246 comes into contact with the end of
the push rod provided on the underside of the cover assembly, which
projects into the docking port of the cover assembly. The manner in
which the push rod operates has been discussed in detail above;
however, when the refill unit 200 is in its refill position, the
solenoid assembly can cause the push rod to extend and push the
actuator shaft 246 into contact with the arm 248 of the rod 236 so
as to disengage the pawl 240 with the ratchet 242, following which
the push rod returns to its retracted position. Then, once the pawl
240 re-engages through action of the actuator spring 244, the arm
248 of the rod 236 pushes the actuator shaft 246 back so as to be
exposed again for subsequent contact by the push rod.
[0602] More ink is refilled from the refill unit 200 through
repeated actuation of the push rod by the solenoid assembly,
delivering controlled amounts of refill ink each time. As such, the
refill cartridge is provided with the ability to perform multiple
refilling operations.
[0603] The status of the amount of the ink stored within the refill
unit 200 is monitored by a quality assurance (QA) control chip 250
provided in the base assembly 202. Initially, the QA chip 250 may
store information in a memory thereof such as the ink capacity of
the tank 226 (e.g., about 50 ml), the amount of ink which will be
ejected from the tank with each pawl/ratchet 240/242 shift (e.g.,
about 6 ml), the colour of the ink stored within the tank and the
position of the working outlet 208.
[0604] In this regard, a sensor or other means is provided
connected to the QA chip 250 which senses either the position of
the pawl/ratchet or the number of times the rod 236 has been
rotated by the actuator shaft 246 or some other mechanism which
informs the QA chip 250 of the remaining capacity/number of refills
of the refill unit. In this regard, the memory of the QA chip 250
is provided as a rewritable memory.
[0605] The QA chip 250 is provided in an exposed position on the
end surface of the base assembly 202, such as in the vicinity of
the hole 202b for the actuator shaft 246 (see FIG. 88), so as to
align and connect with the corresponding QA chip reader provided
within the rim of the docking port of the cover assembly.
[0606] The QA chip reader is connected to a QA chip and/or
controller of the print engine. In this way, the QA chip 250 is
able to communicate the above-described information to the print
engine. For example, the controller of the print engine is able to
check whether the ink storage compartment of the cartridge unit
containing the ink colour/type which matches the refill unit 200
requires refilling by the amount of at least one pawl/ratchet
shift. In response to such determinations, the controller controls
the solenoid assembly so as to operate the push rod the appropriate
number of times to refill the corresponding ink chamber.
[0607] This communication between the refill unit 200 and the print
engine ensures that the correct type/colour of ink and the correct
amount of ink is refilled into the correct ink storage compartment.
Other checks can be performed also, such as correct positioning of
the working outlet 208 on the appropriate refill port of the
cartridge unit.
[0608] In order to deliver the refill ink into the refill ports,
the working outlet 208 of the refill unit comprises a syringe
needle 252 which is connected to the ejection port 228 of the tank
226 through a fluid channel 254 provided on the inner side and
bottom surfaces of the base assembly 202. Sealing between the
ejection port 228 and the fluid channel 254 is provided by an
O-ring 256. The syringe needle 252 is arranged to penetrate the
valve fittings provided within the corresponding ink refill ports
so as to allow the flow of ink into the ink storage
compartments.
[0609] As previously mentioned, the valve fittings may be provided
as an elastomeric seal which seals the ink storage compartments
from the surroundings, thus preventing dust and the like entering
the chambers and providing an elastically walled channel through
which the syringe needle 252 can pass.
[0610] Sealing between the working outlet 208 and the valve
fittings is provided by a seal ring 258 which surrounds the syringe
needle 252. In the refill unit's isolated state, the syringe needle
252 is protected by the seal ring 258 within the working outlet 208
(see FIG. 88). Whereas, in the refill position, the syringe needle
252 is exposed to the valve fitting by action of valve's upper
surface on the seal ring 258 to push the seal ring into the working
outlet 208. The seal ring 258 is able to `ride` up the syringe
needle 252 and upon release from the refill position, the seal ring
is returned to its protection position via action of a seal spring
260 situated between the seal ring and the inner surface of the
fluid channel 254 above the syringe needle. The seal spring 260 is
held to the seal ring 258 with a support washer 262.
[0611] An exemplary refilling operation is illustrated in FIG. 94a
to 94c.
[0612] In FIG. 94a, the refill unit 200 is in its refilling
position with the syringe needle 252 penetrating the valve fittings
of an ink storage compartment of the cartridge unit. At the stage
shown, ink 264 stored within the tank 226 has been primed into the
fluid channel 254 and the syringe needle 252. Alternatively, the
fluid channel 254 may comprise air or other gas at this stage,
e.g., before the first refilling operation for the refill unit has
been performed. The ink is held within this fluid path without
escaping through the syringe needle due to vacuum pressure created
in the fluid path.
[0613] Alternatively, a cap may be provided to be either manually
or automatically fitted within the working outlet so as to cap the
end of the syringe needle. Such a cap additionally provides a means
of ensuring that the stored ink does not dry out before the first
application and between multiple refill applications.
[0614] In FIG. 94b, the actuator arm of the solenoid assembly of
the cradle unit is operated to extend the push bar into contact
with the actuator shaft 246, moving the actuator shaft 246 into
contact against the arm 248 of the rod 236. Immediately after this,
the push bar returns to its retracted position of FIG. 94a. The
pawl 240 is then disengaged from the ratchet groove 242, thus
causing the compression spring 234 to depress the plunger 232 into
the tank 224 in the direction of arrow A. As a result, ink 264 is
ejected from the ejection port 228 and thus through the syringe
needle 252 into the ink storage compartment in the direction of
arrow B.
[0615] In FIG. 94c, the plunger 232 has moved sufficiently for the
pawl 240 to engage with the next ratchet groove 242. At this point,
the plunger 232 is stopped and as such the ejection of the ink 264
from the syringe needle 252 ceases.
[0616] The above process may be repeated until the ink chamber 122
is deemed refilled by the controller of the printer unit or until
the refill unit 200 is depleted of ink. The status of the amount of
ink in the refill unit 200 can be relayed to a user through the
operation of an indicator light 266, such as an LED, provided on
the lid assembly 204. The indicator light 266 is connected to the
QA chip 250 when the lid assembly 204 is fitted to the base
assembly 202, and may be operated to illuminate during the
refilling operation and cease illumination when this operation is
finished and when the refill unit 200 is depleted. Alternatively,
the indicator light 266 may be capable of multi-coloured
illumination, such that different light colours are used to
indicate the particular status of the refill unit 200, e.g., a
green light during refilling; a red light when the refill unit is
depleted.
[0617] Power for the indicator light 266 and the QA chip 250 may be
provided via the connection with the QA chip reader. Alternatively,
a battery may be provided within the refill unit 200 having a power
capacity sufficient for operating the unit until the ink is
depleted.
[0618] An alternative embodiment of a syringe assembly 268 housed
within the refill cartridge 200 is illustrated in FIGS. 95 to 99.
Like the syringe assembly 224 of the previous embodiment, the
syringe assembly 268 is mounted within the base assembly 202 of the
refill unit 200 so as to be covered by the lid assembly 204 and has
the necessary capacity to store and distribute the amount of ink
required for refilling to the print cartridge 102 through the
working outlet 208.
[0619] Like the syringe assembly of the previous embodiment, the
syringe assembly 268 is provided with the tank 226 for storing the
ink within the refill unit 200. The tank 226 has at one end the
ejection port 228 through which the ink is ejected for distribution
and is sealed at the other end by the syringe seal 230. The syringe
seal 230 is mounted on the plunger 232 which plunges into the
hollow internal space of the tank 226 to drive the stored ink out
of the ejection port 228.
[0620] The plunger 232 is plunged into the tank 226 through action
of a compression spring 270 which is attached at one and about the
circumference of the body 232a of the plunger 232. The other end of
the spring 270 acts against a ring 232b fixed between posts 272
which project from the lower internal surface of the base assembly
202. In this arrangement, due to the nature compression spring 270,
it acts to constantly bias the plunger 232 towards the interior of
the tank 226 when the syringe assembly 268 is housed in the base
assembly 202, as did the earlier described embodiment.
[0621] In this instance, control of the plunging operation is
provided by a pawl and ratchet arrangement of the syringe assembly
268. The pawl and ratchet arrangement comprises an actuator rod 274
which is mounted via pins 274a, between its upper and lower ends,
to mounting slots 276 which project from the lower internal surface
of the base assembly 202. In this way, the rod 274 is able to swing
or pivot about the mounted pins 274a.
[0622] The rod 274 has a pawl 278 at its upper end which is
engageable with a series of teeth of a ratchet 280 provided in a
circular arrangement at one end of a feed member 282 (best
illustrated in FIG. 98). The swinging of the rod 274 enables the
pawl to engage and disengage with the ratchet. An actuator spring
284 is provided between a boss 274b, which projects from the lower
end of the rod 274, and an internal surface of the base assembly to
bias the pawl into the ratchet.
[0623] The feed member 282 is in the form of a cylindrical wheel
and is mounted at either end to the posts 272 via pins 272a which
project into axial holes (not shown) in the ends of the feed member
282. In this way, the feed member 282 is able to rotate about its
longitudinal axis. The feed member 282 further comprises a grooved
thread 286 about its circumference at the end opposite the ratchet
280. The grooved thread 286 is used to train a rope 288 about the
feed member 282. One end of the rope is attached to the end of the
grooved thread and the other end of the rope attached to, or
through, the plunger body 232a.
[0624] Prior to shipment of the refill unit 200, the combination of
the rope 288 and grooved thread 286 and the ratchet and pawl
arrangement is used to initially retract the plunger 232 from the
tank 226 so as to provide a space in which to store the ink. In
this regard, the feed member 282 is provided with a gear 290 which
is able to mesh with an external motor gear or the like. Action of
the motor gear rotates the feed member (in a clockwise direction in
the arrangement shown in FIG. 97) whilst the pawl is not engaged
with the ratchet which causes the rope to be wound about the
grooved thread, thus retracting the plunger from the tank 226
against the action of the spring 270.
[0625] Sufficient rotational force is required to compress the
spring 270 and sufficient strength is required in the rope to hold
the plunger in place whilst the spring is compressed. Once the
plunger has been pulled out of the tank in which position the
spring is substantially fully compressed, the pawl is engaged with
the nearest tooth of the ratchet. This engagement provides
sufficient resistance against the plunging of the plunger 232 into
the interior of the tank 226 through action of the compression
spring 270. The tank 226 can then be primed with ink for
shipment.
[0626] Thus, upon first use of the refill unit 200, the pawl 278 is
engaged with the tooth of the ratchet 280 which provides maximum
ink storage capacity within the tank 226. As ink is required to be
ejected from the tank 226 through the ejection port 228 during a
refilling operation, the rod 274 is swung to disengage the pawl
with the tooth of the ratchet. This causes the plunger 232 to
advance into the tank 226 a set distance thereby ejecting a
measured portion of the stored ink through the ejection port 228.
Ejection stops when the pawl 278 engages with the next tooth of the
ratchet 280, which occurs through action of the actuator spring 284
swinging the rod 274 into engagement with the ratchet.
[0627] Additional measured portions of ink can be ejected from the
tank 226 by repeated swinging of the rod 274 thereby causing
engagement/disengagement of the pawl with the ratchet. This
continues until the rope 288 and the compression spring 270 are
fully extended at which point the ink within the tank 226 is
depleted and the refill unit 200 is spent.
[0628] Similar to the previous embodiment, the swinging of the rod
274 to disengage the pawl 278 can be controlled by way of a slider
element provided on the underside of the cover assembly 11
contacting the lower surface of the rod opposite the boss 274b. As
discussed in relation to the previous embodiment, the lid assembly
can be configured such that an end of the slider element projects
into the docking port 157 and through a hole 202c formed in one of
the side walls of the base assembly 202 when the refill unit is
docked with the cartridge unit 10. The other end of the slider
element may be connected to a refill solenoid assembly which is
attached to the cradle unit as described previously.
[0629] In this way, when the refill unit 200 is docked with the
cartridge unit 10 and is in a refill position, the slider element
can be operated to push the rod 274 so as to disengage the pawl 278
with the ratchet 280. Then, once the pawl re-engages through action
of the actuator spring 284, the lower end of the rod 274 is
repositioned for subsequent contact by the slider element.
[0630] More ink is refilled from the refill unit 200 through
repeated sliding of the slider element. Equally, multiple refill
operations using the one refill unit 200 can be performed if any
one refill operation does not deplete the ink contained therein. As
such, the refill unit is provided with the ability to perform
multiple refilling operations.
[0631] The clip arrangement 210 and the arrangement of the syringe
needle 252 in the working outlet 208 and the QA chip 250 is the
same for the refill cartridge incorporating this alternative
syringe assembly 268 as that of the previous embodiment.
[0632] With this alternative embodiment of the syringe assembly 268
a larger volume of ink can be stored within the tank 226 of the
refill unit 200 (e.g., about 50 ml) whilst retaining a similarly
size to that in the previous embodiment. This is because, the space
occupied by the pawl and ratchet arrangement is minimised whilst
retaining a sufficient number of steps for controlled ejection of
ink for refilling.
[0633] FIGS. 100 to 106 illustrate yet another embodiment of an ink
refill unit 400 suitable for use with the print engine of the
present invention.
[0634] The ink refill unit 400 generally comprises a body assembly
402, for housing the various internal components necessary for
storing and delivering the refill ink, and an end cap assembly 404
which fits onto and caps an end of the body assembly 402. The body
and cap assemblies may be moulded from a plastics material.
[0635] As in the embodiments described above, the refill unit 400
contains ink and is intended to be used as a means for refilling
ink storage compartments 24 provided within the cartridge unit 10.
In this regard, the refill unit 400 is configured to dock with the
uppermost surface 60 of the cartridge unit 10 to transfer the ink
contained therein into one or more of the ink storage compartments
24 of the cartridge unit 10 in the manner as discussed
previously.
[0636] In this regard, the refill unit 400 is also arranged with at
least one working outlet 408 (see FIG. 102) for distributing a
particular colour or type of ink contained in the refill unit to
the corresponding ink refill port 61 associated with the desired
ink storage compartment 24 of the cartridge unit 10. That is, if
the refill unit 400 contains cyan ink, the working outlet 408 is
positioned so as to correspond to the ink refill port 61 associated
with the cyan ink storage compartment of the cartridge unit 10 when
the refill unit is in its refilling position.
[0637] Although not shown in the drawings, a clip arrangement
similar to that of the earlier described embodiment may be provided
on the body assembly 402 and within the rim portion 158 of the
docking port 157, to ensure reliable and efficient transfer of ink
from the refill unit 400 to the cartridge unit 10.
[0638] The body assembly 402 of the ink refill unit 400 has
capacity to store a sufficient amount of ink required to refill the
ink storage compartments 24 of the cartridge unit 10. The internal
components of the body assembly 402 are most clearly seen in FIGS.
103 to 106.
[0639] A compressible bellows tank 410 is provided in the body
assembly 402 for storing the ink. In this regard, the bellows tank
is sealed at one end and is provided with an ejection port 412 at
the other end (being the end adjacent the end wall of the body
assembly) through which the ink is ejected for distribution. The
sealed end of the bellows tank 410 abuts a plunger 414 which is
arranged to compress the bellows tank against the end wall of the
body assembly to expel the stored ink out of the ejection port
412.
[0640] The plunger 414 compresses the bellows tank 410 through
action of a gear and thread arrangement. The gear and thread
arrangement comprises a helical geared thread 416 provided about
the circumference of the substantially circular plunger 414 which
mates with an elongate drive gear 418 which is mounted within the
body assembly 402 and extends along the length thereof, and an
internal lead screw thread 420 provided in the substantially
cylindrical internal wall of the body assembly (see FIG. 106). The
lead screw thread 420 is provided with a gap along the length of
the body assembly 402 in which the drive gear 418 sits and is able
to come into contact with the gear teeth in the gear thread 416 of
the plunger 414. An elongate protruded region 422 of the body
assembly 402 is provided to accommodate the drive gear 418 in this
position.
[0641] In this gear and thread arrangement, the plunger 414 is able
to rotate so as to move along the lead screw thread 420. This
movement provides the plunging operation of the plunger against the
bellows tank. The rotation of the plunger is provided by rotation
of the drive gear 418 being imparted to the geared thread 416 of
the plunger. The drive gear 418 is held within the protruded region
422 by a pin 418a provided on one end of the drive gear which
slides into a depression or hole within the internal end wall of
the body assembly 402 and a pin 404a provided in a corresponding
position on the internal surface of the end cap assembly 404 which
slides into a corresponding depression 418b provided on the other
end of the drive gear. Other arrangements are possible however, so
long as the drive gear is free to rotate about its long axis.
[0642] The rotation of the drive gear 418 is driven by a motor gear
124 which meshes with the teeth of the drive gear. The motor gear
124 is driven by a motor which may be mounted to the underside of
the cover assembly 11 of the cradle unit 12. In this arrangement,
similar to those described in the above alternative embodiments,
the motor gear 124 is arranged to project from the surface of the
cover assembly to engage with the drive gear 418 through a slot
422a in the protruded region 422. Those of ordinary skill in the
art will understand that the motorisation of the gear and thread
arrangement may also be provided within the refill unit 400 itself
instead of in the cover assembly 11.
[0643] Control of the plunging operation is provided by the
controlling the operation of the motor responsible for rotating the
motor gear 124, and a suitable gearing ratio may be provided for
reasonably fine control of the plunger movement. As will be
appreciated, the plunging operation provides controlled release of
the ink from the bellows tank 410 through its ejection port
412.
[0644] Upon first use of the refill unit 400, plunger 414 is fully
retracted so as to provide full extension of the bellows tank and
hence maximum ink storage capacity in the refill unit 400. Of
course, suitably sized bellows tanks can be provided within the
same sized refill units 400 for provided different storage amounts,
e.g., 30 ml as opposed to 50 ml, depending on application, the
colour of the ink, etc. Then, as ink is required to be ejected from
the bellows tank 410 during a refilling operation, the motor may be
controlled to rotate the motor gear 124 and the drive gear 418
thereby causing the plunger 414 to compress the bellows tank to
eject some of the stored ink through the ejection port 412. The
amount of ink ejected per rotation of the motor gear 124 can be
readily ascertained to provide metered release of ink into the
cartridge unit 10 as necessary.
[0645] The plunging is continued until the required amount of ink
has been ejected into the ink storage compartments of the cartridge
unit 10. For example, in a single-use refill operation, the entire
contents of the refill unit 400 would be ejected, however in a
multiple-use refill operation, only part of the refill unit's
capacity of ink may be required at one time. In such a multiple-use
regime, more ink can be ejected from the bellows tank by repeated
plunging operations until the ink within the bellows tank has been
depleted. The ink may be dispensed in a series of preselected
amounts, e.g., by a series of preselected numbers of turns of the
plunger 414, until the necessary amount of ink has been dispensed,
or the plunger 414 may be simply turned until it is determined that
the ink chamber has been replenished.
[0646] In order to ensure that the ink does not leak from the
ejection port 412 after a refilling operation has been performed
and ink remains in the bellows tank for subsequent refills,
suitable fluid pressure is retained within the bellows tank 410 at
all times. This is achieved by backing-up the plunger 414 by a
suitable amount once the refilling operation is complete. This is
done by rotating the plunger in the opposite direction so as to
allow slight re-expansion of the bellows tank 410. In this regard,
the sealed end of the bellows tank is preferably attached to the
plunger and the motor provided in the cover assembly 11 is
preferably a bi-directional motor.
[0647] Like the previous embodiments, the status of the amount of
the ink stored within the refill unit 400 is monitored by a QA
control chip 424 provided in the body assembly 402. The QA chip 424
is provided in an exposed position on the surface of the end cap
assembly 404, or alternatively on the end surface of the body
assembly 402, so as to align and connect with a QA chip reader 160
provided in the docking port 157 of the cover assembly 11. The QA
chip reader is in turn connected to the SoPEC devices 126 of the
cradle unit 12 to enable control of the overall refill operation.
In the present embodiment, the QA chip 424 is used to provide
information on the amount of ink (and colour, etc) stored in the
refill unit 400 at any instant to the SoPEC devices 126, so that
the SoPEC devices can control the motor to rotate the motor gear
124 the appropriate number of times to refill the corresponding ink
storage compartment 24.
[0648] In this regard, a sensor or other means may be connected to
the QA chip 424 to sense either the position of the plunger 414 or
the number of times the plunger 414 has been rotated by the drive
gear 418 which informs the QA chip 424 of the remaining
capacity/number of refills of the refill unit 400.
[0649] As with the first embodiment, the working outlet 408 of the
refill unit 400 comprises a syringe needle 426 which is connected
to the ejection port 412 of the bellows tank 410 through a fluid
channel 428 provided on the outer sides of the body assembly 402
(see FIG. 102). Sealing between the ejection port 412 and the fluid
channel 428 is provided by an O-ring 430. The syringe needle 426 is
arranged to penetrate the valve fittings 62 provided within the ink
refill ports 61 of the cartridge unit 10 so as to allow the flow of
ink into the ink storage compartments 24. The arrangement and
operation of the syringe needle 426 is otherwise the same as in the
first embodiment.
[0650] An indicator light (not shown) may be provided on the body
assembly 402 of the refill unit 400 connected to the QA chip 424 so
as to indicate the status of the amount of ink in the refill unit
to a user. Power for the indicator light and the QA chip may be
provided via the connection to the contact 130 of the print cradle
100. Alternatively, a battery may be provided within the refill
unit 400 having a power capacity sufficient for operating the unit
until the ink is depleted.
[0651] While the present invention has been illustrated and
described with reference to exemplary embodiments thereof, various
modifications will be apparent to and might readily be made by
those skilled in the art without departing from the scope and
spirit of the present invention. Accordingly, it is not intended
that the scope of the claims appended hereto be limited to the
description as set forth herein, but, rather, that the claims be
broadly construed.
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