Conduit construction using films

A method of forming a conduit providing fluid communication between respective reservoirs of an ink tank, the method comprising the steps of: (a) forming a first orifice extending through a first external wall portion of an ink tank defining part of a first ink reservoir of the ink tank; (b) forming a second orifice extending through a second external wall portion of the ink tank defining part of a second ink reservoir of the ink tank; and (c) attaching a substrate over the first and second external wall portions at least about a first continuous seal line surrounding both the first and second orifices to define an external conduit communicatively connecting the first ink reservoir with the second ink reservoir.

FIELD OF THE INVENTION

The present invention concerns reservoirs for storing liquid contents and, more specifically, to reservoirs utilized to store liquid ink for inkjet printer applications.

BACKGROUND AND SUMMARY

The present invention concerns containers utilized to house liquids and, more specifically, to containers utilized to house liquid ink for inkjet printer applications. Ink containers may be integral with a printhead or communicatively connected thereto. In applications where replacement ink containers are communicatively connected to a permanent printhead, it is desirable that the container be able to supply ink in a predictable manner. Exemplary replacement ink containers may includes one or more chambers filled or partially occupied by liquid ink. To impart a predictable flow of ink from the container to the printhead, the container may house one or more backpressure mediums. Backpressure mediums are mediums that include pores through which liquids can flow, but that provide a resistance to flow resulting from capillary action. Typical backpressure mediums include felts, foams, and other fibrous mediums having pores sizes imparting predictable resistance to fluid flow from the resulting capillarity.

In order to increase the utilization of ink within a container, it is usually preferred that the backpressure medium occupy as little space as possible to satisfy the breathing requirements of the container. At the same time, less backpressure medium results in less control over the flow of ink from the container. In other words, a balance is generally arrived at that involves providing one chamber of the container having a backpressure medium (backpressure chamber) that is in communication with another chamber of the container housing only liquid ink or a combination of liquid ink and trapped gases (free ink chamber).

Conventional ink containers provide for transfer of liquid ink between free ink chambers and backpressure chambers using one or more openings through internal walls of the container that would otherwise separate the chambers. Typically, one or more internal walls step as a partition, but for an opening through the lower level of the wall to allow ink to travel from the free ink chamber and into the backpressure chamber only when the level of ink within the backpressure chamber drops below a predetermined point. This predetermined point typically coincides with the level of the opening between the chambers so that air bubbles from the backpressure chamber can flow into the free ink chamber to displace liquid ink, thereby driving liquid ink into the backpressure chamber until the level of ink within the backpressure chamber rises and cuts off the opening, discontinuing gaseous transfer into the free ink chamber and liquid ink transfer into the backpressure chamber.

Some embodiments of the instant invention provide an alternative to the internal wall openings and provides conduits that extend outside of the conventional ink container by utilizing a substrate mounted to the exteriors of the chambers that allow communication between the free ink chamber and the backpressure chamber, with or without requiring molding of openings within internal walls. Some embodiments also provide manufacturing alternatives that allow the formation of openings within the internal wall separating the chambers without requiring tooling to be substantially constrained by the dimensions of the ink container.

Some embodiments of the present invention to provide a method of forming a conduit providing fluid communication between respective reservoirs of an ink tank, that include the steps of: (a) forming a first orifice extending through a first external wall portion of an ink tank defining part of a first ink reservoir of the ink tank; (b) forming a second orifice extending through a second external wall portion of the ink tank defining part of a second ink reservoir of the ink tank; and (c) attaching a substrate over the first and second external wall portions at least about a first continuous seal line surrounding both the first and second orifices to define an external conduit communicatively connecting the first ink reservoir with the second ink reservoir.

In an embodiment, the method further includes the step of providing at least one depression in the first and second external wall portions extending between the first and second conduits. In another embodiment, the method further includes the steps of (i) forming a third orifice extending through a third external wall portion of the ink tank defining part of the first ink reservoir; (ii) forming a fourth orifice extending through a fourth external wall portion of the ink tank defining part of the second ink reservoir; and (iii) attaching a second substrate over the third and fourth external wall portions at least about a second continuous seal line surrounding both the third and fourth orifices to define a second external conduit communicatively connecting the first ink reservoir with the second ink reservoir. In a further embodiment, the first orifice is adjacent to a first felt member occupying at least a portion of an internal area of the first ink reservoir, and the second orifice is in direct communication with free ink occupying at least a portion of an internal area of the second ink reservoir.

In yet another embodiment, the first and second substrates include a single substrate and the single substrate comprises the first and second seal lines. In still another more detailed embodiment, the first orifice and the second orifice of the first ink reservoir are adjacent to a first felt member occupying at least a portion of an internal area of the first ink reservoir, the first orifice and the second orifice of the second ink reservoir are in direct communication with free ink occupying at least a portion of an internal area of the second ink reservoir, and the combination of the first conduit and the second conduit provides the exclusive manner for fluids to traverse between the first reservoir and the second reservoir. In a further embodiment, the substrate comprises a polymer film, and the first portion of the film is laminated to an exterior wall of the first ink reservoir and to an exterior wall of the second ink reservoir. In still a further detailed embodiment, the step of laminating the first portion of the substrate to the first ink reservoir and to the second ink reservoir includes at least one of heat staking, laser welding, ultrasonic welding, vibrational welding, and adhesive mounting a film to an exterior wall of the first ink reservoir and to an exterior wall of the second ink reservoir.

Some embodiments described herein include a method of forming a conduit providing fluid communication between respective reservoirs of an ink tank, the method comprising the steps of: (a) forming a first orifice through a wall of an ink tank and into communication with a first reservoir and a second reservoir of the ink tank; and (b) sealing a substrate to the ink tank to overlap the first orifice and form a first by-pass conduit communicatively connecting the first reservoir and the second reservoir.

In a more detailed embodiment, the method further includes the steps of: (i) forming a second orifice through the wall of the ink tank and into communication with the first reservoir and the second reservoir of the ink tank; and (ii) sealing the substrate to the ink tank to overlap the second orifice and form a second by-pass conduit communicatively connecting the first reservoir and the second reservoir. In yet another more detailed embodiment, the first reservoir comprises a free ink reservoir, and the second reservoir comprises a backpressure reservoir that is occupied by a backpressure media. In a further detailed embodiment, the combination of the first conduit and the second conduit provides the exclusive manner for fluids to traverse between the first reservoir and the second reservoirs and the substrate comprises a polymer film.

Some embodiments of the present invention provide an ink tank comprising: (a) a first reservoir for housing a liquid ink, the first reservoir including a first orifice through a wall at least partially defining an interior region of the first reservoir; (b) a second ink reservoir for housing a liquid ink, the second ink reservoir including a first orifice through a wall at least partially defining an interior region of the second reservoir; and (c) a first conduit overlapping the first orifice of the first ink reservoir and the first orifice of the second ink reservoir allowing fluid communication between the first reservoir and the second reservoir, the first conduit defined at least in part by a film mounted to the wall of the first ink reservoir and to the wall of the second ink reservoir.

In a more detailed embodiment, the first reservoir comprises a backpressure chamber housing at least one backpressure medium through which liquid ink traverses prior to exiting through an ink outlet orifice of the backpressure chamber, and the second reservoir comprises a free ink chamber housing liquid ink prior to entering the backpressure chamber. In yet another more detailed embodiment, the free ink chamber and the backpressure chamber share a common wall, and the common wall includes an opening therethrough providing a second conduit between the free ink chamber and the backpressure chamber. In a further detailed embodiment, at least one of the wall of the first reservoir and the wall of the second reservoir includes a furrow extending lengthwise in parallel with a line of travel between the first orifices. In still a further detailed embodiment, the ink tank further comprises: (i) a second orifice through the wall at least partially defining the interior region of the first reservoir; (ii) a second orifice through the wall at least partially defining the interior region of the second reservoir; and (iii) a second conduit overlapping the second orifice of the first ink reservoir and the second orifice of the second ink reservoir to allow fluid communication between the second orifices, the second conduit defined at least in part by a film mounted to the wall of the first ink reservoir and to the wall of the second ink reservoir.

Some embodiments of the present invention provide an ink tank comprising: (a) a first vessel defining a first ink reservoir; (b) a second vessel defining a second ink reservoir; and (c) a first by-pass conduit communicatively connecting the first vessel to the second vessel by way of a first orifice that concurrently exposes the first vessel and the second vessel, the first by-pass conduit comprising a first substrate overlapping the first orifice and enclosing one side of the first orifice to allow sealed fluid communication between the first vessel and the second vessel.

In a more detailed embodiment, the first reservoir comprises a free ink reservoir for supplying liquid ink to the second reservoir, and the second reservoir comprises a backpressure reservoir housing at least one backpressure medium through which liquid ink traverses prior to exiting through an ink outlet orifice of the second vessel. In yet another more detailed embodiment, the first vessel and the second vessel share a common wall that includes an opening therethrough directly linking the first reservoir to the second reservoir. In a further detailed embodiment, the ink tank further comprises a second by-pass conduit communicatively connecting the first vessel to the second vessel by way of a second orifice that concurrently exposes the first vessel and the second vessel. In still a further detailed embodiment, the second by-pass conduit comprises a separate substrate overlapping the second orifice and enclosing one side of the second orifice to allow sealed fluid communication between the first vessel and the second vessel. In a more detailed embodiment, the ink tank further comprises a second by-pass conduit communicatively connecting the first vessel to the second vessel by way of corresponding orifices that expose the first vessel and the second vessel, the second by-pass conduit comprising a second substrate overlapping the corresponding orifices and enclosing a side of the corresponding orifices to allow sealed fluid communication between the first vessel and the second vessel. In a more detailed embodiment, the first substrate and the second substrate comprise a polymer film.

Some embodiments of the present invention provide a method of facilitating fluid communication between chambers of an ink tank, the method comprising the steps of: (a) forming a hole through an exterior wall bounding a first chamber of an ink tank; (b) forming a hole through an exterior wall bounding a second chamber of an ink tank; and (c) sealing a film to the exterior wall of the first chamber and to the exterior wall of the second chamber to encompass the hole of the first chamber and the hole of the second chamber to create an external sealed conduit providing fluid communication between the first chamber and the second chamber.

Some embodiments of the present invention provide a method of establishing countercurrent fluid transfer between areas of an ink tank, the method comprising the step of sealing a film to an exterior surface of an ink tank to define a first sealed exterior passage between at least two compartments of the ink tank, the seal between the film and the exterior surface of the ink tank outlining at least a first opening through the ink tank.

In a more detailed embodiment, the method further comprises the step of sealing a second film to the exterior surface of the ink tank to define a second sealed exterior passage between at least two compartments of the ink tank, the seal between the film and the exterior surface of the ink tank outlining at least a second opening through the ink tank. In yet another more detailed embodiment, the step of sealing the second film to the exterior surface of the ink tank seals the second sealed exterior passage to the exclusion of the first sealed exterior passage. In a further detailed embodiment, the ink tank includes an interior passage through an interior wall of the ink tank providing fluid communication between the first chamber and the second chamber of the ink tank, where the interior passage allows fluid to flow in a first direction from the first chamber to the second chamber, and the first sealed exterior passage allows fluid to flow in a second direction, opposite that of the first direction.

Some embodiments of the present invention provide a method of forming an ink tank, the method comprising: (a) molding at least two ink chambers of an ink tank, each ink chamber is defined by vertical walls that intersect a horizontal wall, where the at least two chambers share a common wall dividing the chambers from one another; (b) forming a first orifice and a second orifice through the horizontal floor, where the second orifice is vertically overlapped by the common wall; (c) mounting a lid to the vertical walls opposite the horizontal wall; and (d) mounting a film over the first orifice and the second orifice to inhibit fluid from egressing through the orifices.

In a more detailed embodiment, the common wall includes an opening therethrough providing fluid communication between the at least two chambers, and the step of forming the second orifice through the horizontal wall includes removing material from the horizontal wall to create the second orifice and further includes removing material from the common wall directly above the second orifice to form the opening through the common wall. In a further detailed embodiment, further comprising the step of: (i) forming a first orifice through a vertical wall defining the first chamber; (ii) forming a first orifice through a vertical wall defining the second chamber; and (iii) mounting a film to the vertical wall of the first chamber and to the vertical wall of the second chamber to encompass the first orifices and provide a sealed conduit between the first chamber and the second chamber.

DETAILED DESCRIPTION

The exemplary embodiments of the present invention are described and illustrated below to encompass reservoirs for storing fluid contents. Of course, it will be apparent to those of ordinary skill in the art that the preferred embodiments discussed below are exemplary in nature and may be reconfigured without departing from the scope and spirit of the present invention. However, for clarity and precision, the exemplary embodiments as discussed below may include optional steps, methods, and features that one of ordinary skill should recognize as not being a requisite to fall within the scope of the present invention.

ReferencingFIG. 1, a first exemplary ink tank10includes a backpressure chamber12and a free ink chamber14partially separated from one another by an internal wall16. An orifice18through the internal wall16provides direct communication between the chambers12,14. Right and left side walls (not shown) are connected to one another by way of a front wall20, a floor22, a lid24, and the internal wall16, which collectively generally define the backpressure chamber12. An outlet opening26is included in the floor22that provides access to the interior of the backpressure chamber12. The opening26is sealed using a film28(or gasket (not shown)) to be removed by a consumer prior to use of the ink tank10. The opening26, subsequent to film28removal, is adapted to accommodate at least partial throughput of a snout of an ink receptacle (not shown) to facilitate transfer of liquid ink from the backpressure chamber to a plurality of nozzles of printhead (not shown).

Two backpressure mediums30,32occupy the interior of the backpressure chamber12. The first backpressure medium30occupies a lower portion, while the second backpressure medium32occupies the top portion. Each backpressure medium30,32includes numerous pores that allow liquid ink and gases to travel through the medium, however, the liquid flow is retarded from gravitationally egressing through the medium by capillary action. In this exemplary embodiment, the first backpressure medium30is typically a higher backpressure and higher density felt, foam, or fiber while the second backpressure medium32is a lower backpressure and lower density felt, foam, or fiber. The pore size of the second backpressure medium32retards the flow of liquid ink to a lesser extent than that of the first backpressure medium30.

A vent34within the lid24is in communication with the second backpressure medium32and the external environment. In this exemplary embodiment, the vent34includes a serpentine trench (not shown) in communication with the vent opening through the lid24that cooperates with an adhesive label36to provide a serpentine conduit (not shown), with a portion of this adhesive label36being removed prior to installation in order to expose the serpentine conduit to the external environment. Thus, as liquid ink flows through the second backpressure medium32to replace the ink withdrawn from the first backpressure medium30via the opening26, gases flow into the backpressure chamber12through the vent34to replace the volume within the backpressure medium32no longer occupied by liquid ink. It is also within the scope of the invention to utilize a vent seal or vent tape (not shown), separate from the adhesive label36, that a user removes prior to installation of the tank10that overlies the exposed end of the serpentine conduit.

The free ink chamber14is also defined by right and left side walls (not shown), the floor22, the lid24, and a rear wall38. In this exemplary embodiment, the free ink chamber14is adapted to be occupied by liquid ink, with no backpressure medium. The floor22includes an orifice40that is sealed using a polymer film42. The application of the film42to the underside of the floor22does not hinder the functionality of the orifice18through the internal wall16. Therefore, liquid ink enters the backpressure chamber12when the level of liquid ink within the backpressure chamber12drops sufficiently to allow gas from the backpressure chamber12to enter the free ink chamber14. As will be discussed in more detail hereafter, the orifices18,40may be formed using a plurality of different techniques.

Fabrication of the exemplary ink tank10includes injection molding the floor22, side walls, front and rear walls20,38, and interior wall16as a single piece structure. When molded in this exemplary process, the interior wall16completely separates the backpressure chamber12from the free ink chamber14. After the single piece structure is molded, it is removed from the mold and processed by a cutting tool (not shown) that creates one opening40or both of the openings26,40within the floor, given that one of the openings26may be formed during the molding process. After forming the opening40through the floor22, the cutting tool continues vertically upward to remove a portion of the internal wall16, thereby forming the orifice18.

Alternatively, the exemplary ink tank10may be fabricated by injection molding the floor22, side walls, front and rear walls20,38, and interior wall16as a single piece structure, along with molding both of the openings26,40within the floor and the orifice18through the interior wall16. Creating the orifice18in this manner does not require utilization of molding slides that might otherwise complicate the molding process.

Regardless of the fabrication approach utilized, the first polymer film28and the second polymer film42are laid over the openings28,40in the floor22to create a fluidic seal across the floor. An adhesive process is performed to mount the first film28to the outlet opening26, whereas a heat staking operation is performed to attach the second film42to the second opening40, thereby inhibiting fluid communication through the outlet orifice26and the opening40. It is to be understood that the first film28is mounted to enable eventual removal, whereas the second film is mounted to inhibit removal. Thereafter, each backpressure medium30,32is inserted into the backpressure chamber12, followed by mounting the lid24to complete the formation of the chambers12,14.

It is to be understood that ink may be added at various stages during the exemplary fabrication process such as, without limitation, after the introduction of the backpressure media30,32, or after mounting the lid24. Moreover, the ink may be introduced after mounting of the lid24by introducing ink through a fill port (not shown) formed through the lid. Those of ordinary skill are familiar with conventional fill ports and the devices utilized to plug the fill ports, such as fill balls, subsequent to an ink fill operation. Therefore, the exemplary fabrication sequence is amendable to many obvious variations incorporating the aforementioned features and process steps.

ReferencingFIGS. 2 and 3, a second exemplary ink tank110includes a backpressure chamber112and a free ink chamber114separated from one another by an internal wall116. An external conduit assembly118connects the chambers112,114to one another for the transfer of gases into the free ink chamber114and the transfer of ink into the backpressure chamber112. The external conduit assembly118is bounded in part by an exterior wall124of the tank110, which may optionally have grooves, pathways or other such depressions125molded or otherwise formed therein, as well as by a polymer film126sealed substantially about its periphery to the exterior wall124that encompasses two inlet/outlet orifices128,130extending through the exterior wall124and further encompassing the depressions125extending between the inlet/outlet orifices128,130. The first inlet/outlet orifice128provides access to the interior of the backpressure chamber112, while the second inlet/outlet orifice130provides access to the interior of the free ink chamber114. Because the continuous seal127between the polymer film126and the exterior wall124surrounds both inlet/outlet orifices128,130, fluid communication is provided between the inlet/outlet orifices128,130. The optional depressions125may also facilitate or improve fluid communication between the inlet/outlet orifices128,130after the film126is sealed over the exterior wall124. Such depressions125could possibly allow the film126to be sealed across the exterior wall's flat surface, thereby allowing for lesser precision in the sealing operation; or the depressions could be used in addition to the surrounding seal127.

The backpressure chamber112acts as a holding area for ink prior to the ink egressing through an outlet orifice132. Four vertical walls116,124,140,142, a floor136, and a top lid138define the interior region of the backpressure chamber112. The interior region is majority occupied by one or more backpressure mediums (not shown) that are in communication with a vent144formed through the top lid138. A second polymer film146is mounted to the floor136and circumscribes the outlet orifice132to inhibit ink from egressing through the outlet orifice. Finally, a label148is adhesively mounted over the lid138and cooperates with the vent144to provide a serpentine conduit (not shown) between backpressure chamber112and an external environment to inhibit ink from egressing from the backpressure chamber112. As with the first exemplary embodiment, a portion of the label148may be removed to expose one end of the serpentine conduit, or a separate a vent seal or vent tape (not shown) may be removed to expose one end of the serpentine conduit.

The free ink chamber114is adapted to house liquid ink prior to the ink being introduced into the backpressure chamber112. In this exemplary embodiment, the interior of the free ink chamber112is defined by four vertical walls116,124,142,150, the floor136, and the top lid138. Ink travels from the free ink chamber114and through the conduit assembly118into the backpressure chamber112when the level of ink within the backpressure chamber112drops sufficiently to allow gas from the backpressure chamber112to enter the conduit assembly118and travel into the free ink chamber114.

Fabrication of the second exemplary ink tank110includes injection molding the floor136, vertical walls116,124,140,142,150as a single piece structure. Each of the orifices128,130,132through, and depressions in, the exterior wall124are molded or are later cut or otherwise formed in the wall124. Thereafter, the first polymer film126is laid over the orifices128,130(and the optional depressions125extending therebetween), while the second polymer film146is laid over the outlet orifice132. In the exemplary embodiment, a heat staking operation is performed to attach the film126to the exterior wall124along a seal127circumscribing collectively the orifices128,130to form the conduit118. The other film146is attached to the underside of the floor136using an adhesive and the film circumscribes the outlet orifice132, thereby inhibiting fluid communication through the outlet orifice132. A backpressure medium (not shown) is inserted into the backpressure chamber112, followed by mounting the lid138to the exposed tops of the walls116,124,140,142,150to complete the formation of the chambers112,114. Ink is also introduced in to chambers112,114, followed by mounting the label148to the lid138.

ReferencingFIGS. 4 and 5, a third exemplary ink tank210includes a plastic unitary body214and a top lid216. The unitary body214includes side walls218,219, a front wall220, an internal wall222, a rear wall224, and a floor226. An orifice228through the internal wall222allows communication between a free ink chamber230and a backpressure chamber232. The top lid216is mounted to the exposed end of the unitary body214and includes a vent234allowing communication between an external environment and the interior of the backpressure chamber232.

An external conduit assembly236also provides communication between the respective chambers230,232. The conduit assembly236is defined by the cooperation of a film238mounted substantially about its periphery to the exterior of the side wall218, where the seal239between the wall218and the film238surrounds two inlet/outlet orifices240,242formed through the side wall218. One of the inlet/outlet orifices240leads into the interior of the backpressure chamber232, while the other inlet/outlet orifice242leads into the interior of the free ink chamber230. Depressions243within the side wall218run between the orifices240,242and are operative to provide fluid communication between the inlet/outlet orifices240,242.

Even when an outlet orifice244of the backpressure chamber232is sealed by a second film246, and the vent234is sealed by a label248or other sealing material, the ink and gases may be exchanged between the chambers230,232via the external conduit assembly236to accommodate for pressure changes exerted upon the fluids within the chambers230,232. In a preferred installation and subsequent operation, a portion of the label248and the entire film246are removed, and ink flows from the backpressure chamber232through the orifice244and gases flow into the backpressure chamber232by way of the vent234in order to replace the volume previously occupied by liquid ink. Preferably, the backpressure chamber232houses a saturated medium, while the free ink chamber houses ink. Eventually, the level of ink within the backpressure chamber232drops and allows gas within the backpressure chamber232to be exposed to the inlet/outlet orifice240. At this point, a transfer cycle is created similar to that between the vent234and outlet orifice244, where gas from the backpressure chamber232enters the free ink chamber230by way of the conduit assembly236, and ink travels from the free ink chamber230into the backpressure chamber232in an amount roughly equal to the volume of gas entering the free ink chamber230from the backpressure chamber232. In this manner, gas and ink can freely travel into their respective chambers without the other fluid hindering the progress as the gas can travel via the conduit236and the liquid ink can travel via the opening228. This cycle of gas displacing the liquid ink in the free ink chamber230continues until the level of ink within the backpressure chamber232is below that of the openings228. Gas may travel into the free ink chamber using a combination of the opening228and the conduit assembly236. Continued ejection of the ink from the backpressure chamber232via the outlet orifice244continues until both of the chambers230,232are essentially empty of ink.

Fabrication of this third exemplary ink tank210includes injection molding the floor226, vertical walls218,219,220,222,224, as a single piece structure in which each of the orifices228,240,242,244has already been formed. Thereafter, the first polymer film238is heat staked to form an outline seal surrounding the inlet/outlet orifices240,242, while the second polymer film246is adhesively mounted over the outlet orifice244.

An applicable backpressure medium (not shown) is inserted into the backpressure chamber232, followed by mounting the lid216to the exposed walls of the single piece structure214, thereby completing the formation of the chambers230,232. Ink is then introduced into the chambers by way of an ink fill port (not shown), followed by mounting the label248to the lid216to seal the vent234and render the tank210ready for shipment.

ReferencingFIG. 6, a fourth exemplary ink tank310includes essentially the same structure as the second exemplary ink tank110, but also includes two additional inlet/outlet orifices312,314covered by an additional polymer film316which is heat staked to the exterior wall124forming a seal line317surrounding the inlet/outlet orifices312,314. The orifices312,314, the film316, and the exterior wall124of the tank310cooperate to define a second conduit318to provide two conduits118,318for communication between the free ink chamber114and the backpressure chamber112. Each conduit118,318includes depressions125,325directing fluids (i.e., ink, gas, etc.) between the orifices128,130,312,314. In this manner, as the level of ink drops within the backpressure chamber112below the inlet/output orifice312, gases from the backpressure chamber112travel through the second conduit318in an uninterrupted path, thereby displacing ink with the free ink chamber114traveling into the backpressure chamber via the first conduit118. In this way, ink and gases may flow through the respective conduits118,318in a countercurrent and uninterrupted manner.

Fabrication of the fourth exemplary ink tank310is consistent with those fabrication steps discussed above for the second exemplary ink tank110, in addition to the formation of the orifices312,314. The orifices312,314are molded into the exterior wall124of the floor136and walls116,124,140,150of the tank310. Application of the film316to the exterior wall124is consistent with the processes discussed in the second exemplary embodiment for attaching the first film126to the exterior wall124to maintain a fluidic seal between the film and wall. In this regard, separate pieces of film may be used to fabricate the first and second conduits118,318, or a single piece of film350may be utilized to form the separate conduits118,318to produce a fourth alternate exemplary ink tank310′ (seeFIG. 7). As shown inFIG. 7, the single piece film350is sealed to the exterior wall about a seal line351that surrounds orifices312and314, and a second seal line353that separately surrounds orifices128and130, thus respectively providing conduits318′ and118′. Those of ordinary skill will readily understand how these fourth exemplary embodiments operate and how these fourth exemplary embodiments may be fabricated following the teachings recited above for the alternate exemplary embodiments of the instant invention.

ReferencingFIG. 8, a fifth exemplary ink tank410includes essentially the same structure as the fourth alternate exemplary ink tank310′, but includes a single seal line445surrounding the orifices128,130,312,314. A bridge444is formed within the seal line445that allows direct communication between the conduits118′,318′. In this manner, air bubbles caught within the first conduit118′ can travel through the bridge444and into the second conduit318′.

Fabrication of the fifth exemplary ink tank410is consistent with those fabrication steps discussed above for the second exemplary ink tank110and the fourth alternate exemplary ink tank310′. Instead of sealing the single film350to the exterior wall124to define separate conduits118′,318′, the heat seal line445surrounds the four orifices128,130,312,314and preserves the conduits, while allowing direct communication between the conduits by way of the bridge444.

ReferencingFIG. 9, a sixth exemplary ink tank500includes a single orifice502that bridges the free ink chamber514and backpressure chamber512. A film526is mounted over the orifice502and to an external wall524of the tank500to create a conduit518, defined within a seal line517, that effectively bridges the chambers512,514. Exemplary procedures for mounting the film526to the external wall524include, without limitation, heat staking and laser welding. The exemplary single orifice502may be used in place of the multiple orifices discussed in the first through fifth exemplary embodiments that cooperate to provide entry and exit openings for any of the exemplary conduits discussed herein.

In accordance with the foregoing exemplary embodiments, the films utilized to create the conduits between the free ink chamber and the backpressure chamber include, without limitation, polypropylene films, polyethylene films, copolymer films, metallic films, and composite films (such as polymer films interposing metallic films). In addition, the exemplary films may be mounted to the ink tanks using the exemplary heat staking process, as well as other sealing and bonding processes such as, without limitation, laser welding, ultrasonic welding, vibrational welding, and adhesive. Moreover, the term “film” as used herein is not restricted to the literal meaning. By way of example, and not limitation, the term “film” as used herein also encompasses solid plate material and solid preformed bubble castings or moldings that may be mounted to the exemplary tanks to create the exemplary conduits between chambers.

Following from the above description and invention summaries, it should be apparent to those of ordinary skill in the art that, while the methods and apparatuses herein described constitute exemplary embodiments of the present invention, the invention contained herein is not limited to this precise embodiment and that changes may be made to such embodiments without departing from the scope of the invention as defined by the claims. Additionally, it is to be understood that the invention is defined by the claims and it is not intended that any limitations or elements describing the exemplary embodiments set forth herein are to be incorporated into the interpretation of any claim element unless such limitation or element is explicitly stated. Likewise, it is to be understood that it is not necessary to meet any or all of the identified advantages or objects of the invention disclosed herein in order to fall within the scope of any claims, since the invention is defined by the claims and since inherent and/or unforeseen advantages of the present invention may exist even though they may not have been explicitly discussed herein.