Membrane divided foam for use in an ink jet cartridge

Embodiment of the invention provide an ink jet cartridge for an ink jet printing device. In one embodiment, an ink jet cartridge can include a cartridge body operable to store ink jet printer ink for dispensing from the cartridge. The cartridge can further include at least one dispensing outlet operable to permit ink to be dispensed from the cartridge body. In addition, the cartridge can include a first foam portion positioned adjacent to the at least one dispensing outlet and operable to retain ink within the cartridge body until dispensed from the cartridge body. The cartridge can also include a second foam portion. Furthermore, the cartridge can include at least one membrane disposed between the first foam portion and the second foam portion, wherein the at least one membrane is operable to inhibit ink flow between the first foam portion and the second foam portion.

FIELD OF THE INVENTION

The invention relates generally to ink jet printers, and more particularly, to membrane divided foam for use in an ink jet cartridge, and methods of using the same.

BACKGROUND OF THE INVENTION

Computer printers are well known in the prior art and include dot-matrix printers, piezo-electric ink jet printers, laser printers, thermal ink jet printers, handheld ink jet printers, and other ink jet printing devices. When using an ink jet printing device, an ink jet cartridge can be installed or otherwise mounted to the ink jet printing device to provide a supply of ink.

Ink supplies are often offered to customers at different price points, high yield cartridges container greater quantities of ink and cost ore, while low yield cartridges cost less, but provide less ink to the consumer. To simplify the manufacture of ink supplies, it is sometimes desirable to use the same or a similar-sized cartridge housing for both the high yield and low yield cartridges. As a result, low yield cartridges are sometimes shipped partially filled, which can lead to several problems. In such instances, vibration and environment changes can cause ink to migrate throughout the interior body of the ink jet cartridge such that the ink becomes overly dispersed within the interior body of the ink jet cartridge. In these instances, problems such as depriming and starvation can occur when an insufficient amount of ink is available for dispensing from the ink jet cartridge.

To facilitate lower yield volumes for ink jet cartridges, one conventional ink jet cartridge can include one or more interior walls within the interior body of the ink jet cartridge. In such instances, relatively small interior compartments can be created within the cartridge. In this manner, a relatively small amount of ink can be compartmentalized within the ink jet cartridge, and the ink can be dispensed from an adjacent outlet in the cartridge. However, manufacturing these conventional ink jet cartridges can require retooling the associated manufacturing or assembly processes or otherwise providing a special mold to provide unique geometry and chamber size within the interior body of the ink jet cartridge. Retooling such processes can be time consuming and expensive, particularly when production demand shifts between low and high ink volumes for ink jet cartridges.

SUMMARY OF THE INVENTION

Some or all of the above needs can be addressed by some or all of the embodiments described herein. According to one embodiment of the invention, an ink jet cartridge for an ink jet printing device can include a cartridge body operable to store ink jet printer ink for dispensing from the cartridge. In addition, the cartridge can include at least one dispensing outlet operable to permit ink to be dispensed from the cartridge body. Furthermore, the cartridge can include a first foam portion positioned adjacent to the at least one dispensing outlet and operable to retain ink within the cartridge body until dispensed from the cartridge body. In addition, the cartridge can include a second foam portion. Furthermore, the cartridge can include at least one membrane disposed between the first foam portion and the second foam portion, wherein the at least one membrane is operable to inhibit ink flow between the first foam portion and the second foam portion.

In one aspect of this embodiment, the first foam portion is mounted to one side of the at least one membrane, and the second foam portion is mounted to another side of the at least one membrane.

In another aspect of this embodiment, the first foam portion is hear laminated to one side of the at least one membrane, and the second foam portion is heat laminated to another side of the at least one membrane.

In yet another aspect of this embodiment, the first foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, or an unfelted foam-type material.

In yet another aspect of this embodiment, the second foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, or an unfelted foam-type material.

In yet another aspect of this embodiment, the at least one membrane comprises at least one of the following: polyolefin, polypropylene, polyethylene, polyvinylchloride, or acetate.

According to another embodiment of the invention, a method for operating an ink jet cartridge for an ink jet printing device can include providing an ink jet cartridge. The ink jet cartridge can include at least one dispensing outlet operable to permit ink to be dispensed from the ink jet cartridge. In addition, the ink jet cartridge can include a first foam portion positioned adjacent to the at least one dispensing outlet and operable to retain ink within the cartridge body until dispensed from the cartridge body. The ink jet cartridge can also include a second foam portion. Furthermore, the ink jet cartridge can include at least one membrane disposed between the first foam portion and the second foam portion, wherein the at least one membrane is operable to inhibit ink flow between the first foam portion and the second foam portion. The method can further include mounting the ink jet cartridge in an ink jet printing device, and dispensing ink from the at least one dispensing outlet onto a material.

In one aspect of this embodiment, the first foam portion is mounted to one side of the at least one membrane, and the second foam portion is mounted to another side of the at least one membrane.

In another aspect of this embodiment, the first foam portion is heat laminated to one side of the at least one membrane, and the second foam portion is heat laminated to another side of the at least one membrane.

In yet another aspect of this embodiment, the first foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, or an unfelted foam-type material.

In yet another aspect of this embodiment, the second foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, or an unfelted foam-type material.

In yet another aspect of this embodiment, the at least one membrane comprises at least one of the following: polyolefin, polypropylene, polyethylene, polyvinylchloride, or acetate.

According to another embodiment of the invention, a method for assembling an ink jet cartridge for an ink jet printing device can include providing a cartridge body. The cartridge body can be operable to store ink jet printer ink for dispensing from the cartridge body, wherein the cartridge body comprises at least one dispensing outlet operable to permit ink to be dispensed from the cartridge body. Furthermore, the method can include mounting a first foam portion to one side of at least one membrane, wherein the first foal portion is operable to retain ink within the cartridge body until dispensed from the cartridge body. The method can also include mounting a second foam portion is another side of the at least one membrane. In addition, the method can include disposing the first foam portion, the at least one membrane, and second foam portion within the cartridge body, wherein the first foam portion is positioned adjacent to the at least one dispensing outlet and operable to retain ink within the cartridge body until dispensed from the cartridge body, and wherein the at least one membrane is operable to inhibit ink flow between the first foam portion and the second foam portion.

In one aspect of this embodiment, the method can further include inserting ink into the cartridge body, wherein the ink is retained within the first foam portion.

In another aspect of this embodiment, the first foam portion is heat laminated to one side of the at least one membrane, and the second foam portion is heat laminated to another side of the at least one membrane.

In yet another aspect of this embodiment, the first foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, an unfelted foam-type material, or any combination thereof.

In yet another aspect of this embodiment, the second foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, an unfelted foam-type material, or any combination thereof.

In yet another aspect of this embodiment, the at least one membrane comprises at least one of the following: polyolefin, polypropylene, polyethylene, polyvinylchloride, or acetate.

According to yet another embodiment of the invention, an apparatus for an ink jet cartridge for an ink jet printing device can include a first foam portion positioned adjacent to a dispensing outlet of an ink jet cartridge and operable to retain ink within the ink jet cartridge until dispensed from the ink jet cartridge. The apparatus can also include a second foam portion. In addition, the apparatus can include at least one membrane disposed between the first foam portion and the second foam portion, wherein the at least one membrane is operable to inhibit ink flow between the first foam portion and the second foam portion when the first foam portion and second foam portion are disposed within an ink jet cartridge.

In one aspect of this embodiment, the first foam portion is mounted to one side of the at least one membrane, and the second foam portion is mounted to another side of the at least one membrane.

In another aspect of this embodiment, the first foam portion is heat laminated to one side of the at least one membrane, and the second foam portion is heat laminated to another side of the at least one membrane.

In yet another aspect of this embodiment, the first foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, or an unfelted foam-type material.

In yet another aspect of this embodiment, the second foam portion comprises at least one of the following: polyurethane, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, or an unfelted foam-type material.

In another aspect of this embodiment, the at least one membrane comprises at least one of the following: polyolefin, polypropylene, polyethylene, polyvinylchloride, or acetate.

Other systems, processes, and apparatus according to various embodiments of the invention will become apparent with respect to the remainder of this document.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION

FIG. 1shows a perspective view of an example ink jet printer cartridge100, according to an embodiment of the invention. The example ink jet printer cartridge100shown inFIG. 1includes a cartridge body102. The cartridge body102can include a relatively durable compartment or container for mounting within or to an ink jet printing device and for dispensing an ink jet ink in a printing application. The ink jet printer cartridge100can also include one or more dispensing outlets104for dispensing ink from the cartridge body102. As shown, the dispensing outlets104can be oriented to permit ink within the cartridge body102to be dispensed from a particular portion of the body102, such as an extended printer head portion106. Shown within the cartridge100, a first foam portion110and second foam portion108are disposed on opposing sides of a membrane112. Generally, the membrane112can separate the first foam portion110and the second foam portion108when both foam portions108,110are disposed within the cartridge body102. Alternatively, the membrane112can separate the cartridge body102into two or more regions with the first foam portion110in one region and the second foam portion108in another region of the cartridge body102. In this example, the first foam portion110can be oriented adjacent to the dispensing outlets104and extended printer head portion106, while the second foam portion108can be oriented away from the dispensing outlets104. In this manner ink jet114can be maintained and dispensed from a particular portion of the cartridge body102, specifically from a region adjacent to the dispensing outlets104and extended printer head portion106. For instance, a suitable back pressure can be generated by the internal configuration of the ink jet cartridge100capable of maintaining ink114within the cartridge body102until dispensed. An associated ink jet printing device (not shown) can interact with the ink jet printing cartridge100and dispense ink jet ink114from the cartridge body102in a printing application as needed.

Other embodiments can include different configurations and numbers of foam portions and membranes disposed within a cartridge body of an ink jet printer cartridge in accordance with other embodiments of the invention.

In one embodiment, a suitable first foam portion can include reticulated polyurethane, or any other foam-type material operable to retain an ink jet ink within an ink jet cartridge. One example of a suitable first foam portion is an unfelted, approximately 93 ppi (pores per inch), reticulated charcoal, polyether-polyurethane foam. Other suitable materials for a first foam portion can include, but are not limited to, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, an unfelted foam-type material, or any combination thereof.

In one embodiment, a suitable second foam portion can include reticulated polyurethane, or any other foam-type material operable to retain an ink jet ink within an ink jet cartridge. One example of a suitable second foam portion is an unfelted, approximately 93 ppi, reticulated charcoal, polyether-polyurethane foam. Other suitable materials for a second foam portion can include, but not limited to, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, an unfelted foam-type material, or any combination thereof.

In one embodiment, a suitable membrane can include polyolefin, polypropylene, polyethylene, or any other flexible-type material operable to separate regions within an ink jet cartridge and further operable to inhibit ink flow between a first region and a second region within an ink jet cartridge. One example of a suitable membrane is a polyolefin membrane. Other suitable materials for a membrane can include, but are not limited to, polypropylene, polyethylene, polyvinylchloride, or acetate.

In one embodiment, the first foam portion and second foam portion can each be heat laminated to opposing sides of the membrane. In other embodiments, the membrane may be sufficiently mounted to both the first foal portion and second foam portion using a suitable amount of heat and/or pressure. In yet other embodiments, the membrane may be sufficiently mounted to both the first foam portion and the second foam portion using either or both a heat lamination process and a suitable adhesive.

In one embodiment, the first foam portion and the second foam portion can be different types of foam or materials mounted to opposing sides of a membrane.

In one embodiment, the ink within an ink jet cartridge, such as ink114in cartridge100shown inFIG. 1, can have a back pressure of approximately 2 to 3 cm (0.787 to 1.181 inches) of water when the cartridge is assembled and ink is stored inside the cartridge for subsequent dispensing.

FIG. 2shows a perspective view of an example apparatus200for an ink jet cartridge100.FIG. 3shows an end view of the example apparatus shown inFIG. 2, andFIG. 4shows a side view of the example apparatus shown inFIG. 2. The example apparatus200shown inFIGS. 2-4includes a first foam portion202, a second foam portion204, and a membrane206. In this example, the first foam portion202and second portion204are disposed on opposing sides of the membrane206. The first foam portion202and the second foam portion204are each mounted or heat laminated to the membrane206. In at least one embodiment, the first foam portion202and second foam portion can be mounted to the membrane206using a suitable adhesive. In yet another embodiment, the membrane may be sufficiently mounted to both the first foam portion and the second foam portion using both a heat lamination process and a suitable adhesive. Generally, the membrane206can separate the first foam portion202from the second foam portion204when the apparatus200is disposed within an ink jet printer cartridge, such as100inFIG. 1.

The first foam portion202is shown as a rectangular-shaped polygon. In one embodiment, a suitable first foam portion can include reticulated polyurethane, or any other foam-type material operable to retain an ink jet ink within an ink jet cartridge. One example of a suitable first foam portion is an unfelted, approximately 93 ppi, reticulated charcoal, polyether-polyurethane foam with the approximate dimensions of 31 millimeters (mm) (1.22 inches×33 mm (1.30 inches)×33 mm (1.30 inches). Other embodiment of a first foam portion can have different shapes, sizes, an material composition depending on the size and shape of the ink jet cartridge and the type of ink to be used with the first foam portion. Other suitable materials for a first foam portion can include, but are not limited to, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, an unfelted foam-type material, or any combination thereof.

The second foam portion204is shown as a rectangular-shaped polygon. In one embodiment, a suitable second foam portion can include reticulated polyurethane, or any other foam-type material operable to retain an ink jet ink within an ink jet cartridge. One example of a suitable second foam portion is an unfelted, approximately 93 ppi, reticulated charcoal, polyether-polyurethane foam with the approximate dimensions of 31 millimeters (mm) (1.22 inches)×33 mm (1.30 inches)×33 mm (1.30 inches). Other embodiments of a second foam portion can have different shapes, sizes, and material compositions depending on the size and shape of the ink jet cartridge, and the type of ink to be used with the second foam portion. Other suitable materials for a second foam portion can include, but are not limited to, polyester, polyether, polyolefin, a foam, a reticulated foam-type material, an unreticulated foam-type material, a felted foam-type material, an unfelted foam-type material, or any combination thereof.

In one embodiment, the first foam portion202and the second foam portion204can be different types of foam or materials.

The membrane206is shown as a relatively thin, rectangular-shaped structure. In one embodiment, a suitable membrane can include polyolefin, polypropylene, polyethylene, or any other flexible-type material operable to separate regions within an ink jet cartridge and further operable to inhibit ink flow between a first region and a second region within an ink jet cartridge. One example of a suitable membrane is a polyolefin membrane with the approximate dimensions of 33 millimeters (mm) (1.30 inches)×33 mm (1.30 inches)×0.05 mm (0.0020 inches). Other embodiments of a membrane can have different shapes, sizes, and material compositions depending on the size and shape of the ink jet cartridge, and the type of ink to be used with the membrane. Other suitable materials for a membrane can include, but are not limited to, polypropylene, polyethylene, polyvinylchloride, or acetate.

In the embodiment shown, the foam portions202,204can be mounted to opposing sides of the membrane206using a heat lamination process. In other embodiments, a suitable adhesive can be applied between the membrane206and each of the foam portions202,204. In one embodiment, a suitable adhesive can include any adhesive-type material operable to mount a first or second foam portion to one side of a membrane. In another embodiment, the membrane206may be sufficiently mounted to both the first foam portion202and second foam portion204using a suitable amount of heat and/or pressure. In other embodiments, other mounting techniques, laminates, adhesives, or other devices can be used to mount each from portion to a side of a membrane.

FIGS. 5A-Dillustrate an example method for assembling an ink jet cartridge for an ink jet printing device, or otherwise assembling an apparatus for an ink jet cartridge, according to illustrative embodiments of the invention. The ink jet cartridge and apparatus shown inFIGS. 5A-Dis similar to the cartridge100described inFIG. 1, and apparatus200inFIGS. 2-4.

The method500begins inFIG. 5A, where a first foam portion502, similar to108inFIG. 1, is mounted to one side of a membrane504, similar to112. The first foam portion504is operable to retain ink within a printer cartridge body until dispensed from the printer cartridge body, and the membrane504can be operable to inhibit ink flow between the one portion of a printer cartridge body and another portion of the printer cartridge body. In this example, the first foam portion can be reticulated polyurethane, and the member can be polyethylene.

In one embodiment, a heat lamination process can be used to mount the first foam portion502to one side of the membrane504. For example, a suitable amount of heat can be applied to either or both the first foam portion502and one side of the membrane504. In another example, a suitable adhesive can be applied between the first foam portion502and one side of the membrane504. In either instance, an appropriate amount of heat and/or pressure may be applied such that the membrane504and the foam portion502mount to each other, or otherwise activate the adhesive to permit the first foam portion502to substantially adhere to the one side of the membrane504. In another embodiment, the membrane504may be sufficiently mounted to both the first foam portion502and second foam portion506using a suitable amount of hear and/or pressure. In other embodiments, other mounting techniques, laminates, adhesives, or other devices can be used to mount a first foam portion to one side of a membrane.

InFIG. 5B, a second foam portion506, similar to106inFIG. 1, is mounted to another side of the membrane504. In this example, the second foam portion can be reticulated polyurethane.

In one embodiment, a heat lamination process can be used to mount the second foam portion506to another side of the membrane504. For example, a suitable amount of heat can be applied to either or both the second foam portion506and another side of the membrane504. In another example, a suitable adhesive can be applied between the second foam portion506and one side of the membrane504. In either instance, an appropriate heat and/or pressure may be applied such that the membrane504and the foam portion506mount to each other, or otherwise to activate the adhesive to permit the second portion506to substantially adhere to the other side of the membrane504. In other embodiments, other mounting techniques, laminates, adhesives, or other devices can be used to mount a second foam portion to one side of a membrane.

In one embodiment, the combination of the first foam portion502, membrane504, and second foam portion506comprises an apparatus for an ink jet printer cartridge, such as printer cartridge508.

InFIG. 5C, an ink jet printer cartridge508, similar to100inFIG. 1, with a cartridge body510, similar to102inFIG. 1, is provided. The cartridge body510shown can be operable to store ink jet printer ink for dispensing from the cartridge510. In this example, the cartridge body510can include at least one dispensing outlet512, similar to104, operable to permit ink to be dispensed from the cartridge body510. As shown inFIG. 5C, a funnel514and/or other insertion tools can be used to dispose the assembled first foam portion502, the membrane504, and second foam portion506, or apparatus, within the cartridge body510, wherein the first foam portion502is positioned adjacent to the at least one dispensing outlet512. Appropriate pressure or force may be needed to compress and manipulate the first foam portion502, the membrane504, and second foam portion506into and through the funnel514for insertion into the cartridge body510. In other embodiments, other insertion tools, devices, or techniques can be use to dispose a first foam portion502, a membrane504, and a second foam portion506within a cartridge body510.

In the embodiment shown inFIG. 5C, an upper portion of the cartridge body510has been removed to permit insertion of the assembled first foam portion502, the membrane504, and second foam portion506, or apparatus, within the cartridge body510. The assembled first foam portion502, the membrane504, and second foam portion506, or apparatus, can be rotated, compressed, or otherwise manipulated as needed to fit within the cartridge body510. In other embodiments of the invention, relatively smaller, larger, or other portions of the cartridge body510can be removed, or a relatively small opening can be used, to insert the apparatus into the cartridge body510.

As shown inFIG. 5D, the assembled first foam portion502, the membrane504, and second foam portion506, or apparatus, can be disposed within the cartridge body510. In this embodiment, the first foam portion502is shown adjacent to the at least one dispensing outlet512. In this manner the first foam portion502will be operable to retain ink within the cartridge body510until dispensed from the cartridge body510, and the membrane504will be operable to inhibit ink flow between the first foam portion502and the second foam portion506.

In one embodiment, an additional element of the method500can be inserting ink, similar to114toFIG. 1, into the cartridge body510, wherein the ink can be retained within the first foam portion502. In this example, the ink can be an ink suitable for use as an ink jet printer ink. Generally, after insertion of the apparatus and ink into the cartridge body510, the body510can be sealed or otherwise closed. In the example shown, a corresponding upper portion can be mounted to the cartridge body510, and the cartridge body510can be sealed or closed.

Other methods for assembling an ink jet cartridge for an ink jet printing device, or otherwise assembling an apparatus for an ink jet cartridge, can include some or all of the above elements as well as other elements in accordance with the invention.

FIG. 6illustrates an example set of test data for ink jet cartridges according to an illustrative embodiment of the invention. The ink jet cartridges from which the test data600was collected from are similar to the cartridges100,200described inFIGS. 1-4. The data600is shown graphed with respect to an x-axis602representing ink delivered measured in milliliters (ml) ranging from approximately 0 to 8, and a y-axis604representing back pressure measured in centimeters of water ranging from approximately 0 to 25. A first curve606represents a data set measured for an ink jet cartridge containing a 18C series mono reticulated membrane foam with approximately 93 ppi and filled with approximately 9.0 grams of ink. The second curve608represents a data set measured for an ink jet cartridge containing a 18C series mono reticulated membrane foam with approximately 93 ppi and filled with approximately 9.0 grams of ink. Generally, the first curve606and second curve608slope upward on the graph, and each has a slightly less steep slope than data curves610and612. The third curve610and fourth curve612each represent a data set measured for an ink jet cartridge containing a 18C series mono reticulated membrane foam with approximately 93 ppi and filled with approximately 8.0 grams of ink. The third curve610and fourth curves610and612have similar upward slopes on the graph, but each has a slightly greater slope than data curves606,608. In all instances shown, a quantity of ink can be dispensed from the ink jet cartridges tested before the back pressure dramatically increases, indicating the ink level within the cartridge is nearing or has reached exhaustion. In this manner, desired yield targets in terms of the number of pages printed using each ink jet printer cartridge can be compared by reference to some or all of the curves shown inFIG. 6.