Remote ink supply

Apparatus and methods are provided. A supply of ink within a flexible bag is located apart from a printer. A fluid conduit couples the supply of ink to the printer by way of a connecting head. The connecting head includes a pump driven by a mechanical actuator of the printer. Operation of the pump causes a flow of ink from the flexible bag to a printhead of the printer. Pump failure is detected and interpreted as an out-of-ink condition, and user notification and/or cessation of printing operations are automatically performed.

BACKGROUND

Inkjet printers utilize liquid ink to form images on media. Such printers typically use numerous colors of ink in order to provide color saturation and resolution in accordance with the expectations of the user. Traditionally, such inks are supplied to a printer by way of replaceable cartridges that are supported substantially or entirely within the housing of the printer.

However, users are often dissatisfied with the limited volume of ink that such cartridges provide, resulting in undesirably frequent replacement. The present teachings address the foregoing and other concerns.

DETAILED DESCRIPTION

Introduction

Means and methods for providing ink from one or more remote sources to a printer are provided by the present teachings. Connecting heads are mechanically engaged to respective ink cartridge receiving ports of the printer. Each connecting head includes a pump that is mechanically powered by an actuator of the printer. Each pump serves to drive the flow of an ink from one of the remote sources through connecting conduits to a printhead of the printer. Check valves prevent the backflow of ink from the printer to corresponding remote sources. Failure of a particular pump is detected by a sensor of the printer and interpreted as an out-of-ink condition. One or more alert messages and/or indications are provided to a user in response to the out-of-ink detection.

In one embodiment, an apparatus includes a connecting head configured to be mechanically coupled to a printer, and fluidically coupled to a remote supply of ink. The connecting head including a pump and a check valve. The pump is configured to cause a flow of the ink by way of reciprocations of a flexible diaphragm. The check valve is configured to prevent the ink from flowing from the pump back to the remote supply of ink. The connecting head is configured to be fluidly coupled to a print head of the printer by way of a fluid conduit.

In another embodiment, a printing system includes a printer including a printhead and an ink cartridge receiving port. The printing system also includes a flexible bag that is configured to contain ink. The flexible bag is remotely located with respect to the printer. The printing system further includes a connecting head configured to be disengagably coupled to the ink cartridge receiving port. The connecting head includes a positive displacement pump driven by an actuator of the printer. The pump is configured to cause ink to flow from the flexible bag to the printhead by way of respective fluid conduits.

In yet another embodiment, a method includes imparting at least one force pulse upon a flexible diaphragm of a pump by way of a printer actuator. The method also includes detecting a failure of the flexible diaphragm to reciprocate in response to the at least one force pulse. The method also includes providing a signal in response to the detecting the failure by way of a printer sensor. The method further includes interpreting the signal as an out-of-ink condition of a remote ink supply coupled to the printer. The interpreting is performed by way of a printer controller. The method also includes issuing a user notification of the out-of-ink condition by way of the printer controller.

First Illustrative Embodiment

Reference is now directed toFIG. 1, which depicts a schematic view of a printing system100. The system100is illustrative and non-limiting with respect to the present teachings. Thus, other systems can be configured and/or operated in accordance with the present teachings.

The system100includes a printer102. The printer102includes a controller104configured to control various normal operations of the printer102. The controller104can be defined by any suitable controller, and can include one or more processors, one or more microcontrollers, application-specific integrated circuitry, state machine logic, analog and/or digital circuits, etc. One having ordinary skill in the printing and related arts can appreciate that the controller104can be various defined and configured, and that further elaboration is not required for purposes of understanding the present teachings.

The printer102also includes a printhead106having a pressure regulator108. The printhead106includes a plurality of ink ejection nozzles configured to apply liquid ink to a media110under the control of controller104. The printhead106has one or more pressure regulators108which are configured to receive a respective color of liquid ink by way of flexible conduits112and to regulate the pressure of that color of ink as it is provided to the respective ink ejection nozzles of the printhead106.

The printer102further includes a plurality of actuators114positioned along a receiving bay116. Each of the actuators114is configured to provide force pulses to a respective ink pump under the influence of the controller104. The actuators114can be defined by any suitable mechanical device configured to provide a controllable force pulse. In one embodiment, each actuator114is a mechanically-actuated piston. Other embodiments can also be used. Further elaboration regarding the operation of the actuators114is provided hereinafter. The receiving bay116defines a number of ink cartridge receiving ports118.

The printing system100also includes a plurality of ink supplies120through126, inclusive. Each ink supply120-126includes a respective flexible walled ink bag (or sack)128. In turn, each flexible bag128is configured to contain a quantity of liquid ink of a respective color. In one embodiment, each flexible bag128is formed from a multi-layer layer material which may include nylon, silver, aluminum, linear low density polyethylene or other materials chosen for strength, compliance and low permeability. See, for non-limiting example, U.S. Pat. No. 6,158,853 or U.S. Patent Application Publication No. 20060017788 A1. Other materials can also be used. As depicted, the system100includes four colors of ink (e.g., black, cyan, magenta and yellow). Other systems including other numbers and/or colors of ink are also contemplated by the present teachings. Additionally, each flexible bag128is configured to decrease in internal volume as the ink within is drawn away and consumed, resulting in a vacuum backpressure within the respective flexible bag128.

Each flexible bag128further includes a septum130that is configured to seal the flexible bag128against leaking or other loss of the ink inside. Thus, each septum130can also be referred to as a self-sealing septum130. Each septum130can be formed from polyisoprene, EPDM, combinations thereof, or another suitable flexible material. Each septum130is further configured to be penetrated (opened) by way of hollow needle132inserted there through. Each hollow needle132is fluidly coupled to a flexible conduit134. In this way, the ink within a particular flexible bag128can be fluidly coupled to the printer102by way of a hollow needle132and a flexible conduit134.

The printing system100also includes a plurality of connecting heads136. Each connecting head136includes a check valve138and a pump (seeFIG. 2), and is configured to be selectively coupled and uncoupled (i.e., mechanically engaged and disengaged) from a respective one of the ink cartridge receiving ports118. Additionally, each of the connecting heads136is coupled to a one of the ink supplies120-126by way of a respective flexible conduit134. The check valves138are configured to prevent ink from flowing back into the respective flexible bags128. Thus, the printing system100is configured such that ink flows in one direction only—from the ink supplies120-126to the printer102by way of the conduits134and the connecting heads136.

Attention is now directed toFIG. 2, which depicts selected details of the printing system100. As introduced above, the connecting head136includes a pump200. The pump200includes a flexible diaphragm202. The diaphragm202is generally dome (or convex) shaped and formed from any suitable flexible material such as EPDM, butyl, EPDM/butyl blends, etc. Other materials can also be used. The flexible diaphragm202is disposed adjacent to a pump chamber (or cavity)204defined by the material of the connecting head136. As depicted inFIG. 2, the flexible diaphragm202is in a distended state or condition, and is urged into such a distended state by way of a spring206.

The connecting head136also includes the check valve138, which is defined by a flexible gate or disk208. The flexible gate208can be formed from silicone or another suitable material. The flexible gate208is configured to seal off an inlet passageway210to the pump chamber204when the flexible diaphragm202is being acted upon by an outside force (i.e., actuator114). In this way, the check valve138prevents the flow of ink from the pump chamber204back through the inlet passageway210during normal operations of the pump200. Thus, the flow of ink within the connecting head136is a one-way operation: through the inlet passageway210and into the pump chamber204.

Still referring toFIG. 2, normal operations proceed as follows: the actuator114applies a force pulse against the flexible diaphragm202under influence of the controller104. The flexible diaphragm202transitions from a distended state to a collapsed state under the force of the actuator114, thus reducing the internal volume of the pump chamber204. Ink flows out of the pump chamber204through an outlet passageway212and into a fluid conduit112that couples the ink to a printhead (e.g.,106). The check valve138serves to prevent ink from flowing out of the pump chamber204by way of the inlet passageway210.

Once the flexible diaphragm202has achieved the collapsed state, the force pulse from actuator114is ended (under automatic control). At this point in the operation, the internal volume of the pump chamber204is at a minimum, and the flow of ink ceases. Thereafter, the spring206operates to urge (i.e., push or bias) the flexible diaphragm202back toward the original distended state. As the flexible diaphragm202transitions from the collapsed to the distended condition, the internal volume of the pump chamber204increases. The increasing volume of the pump chamber204serves to draws ink from the fluid conduit134through the inlet passageway210and the check valve138, thus refilling the pump chamber204. Of course, the ultimate source of the ink is the corresponding ink bag128as depicted inFIG. 1. The pressure regulator108of the printhead106may include a check valve mechanism (not shown) that prevents the pump200from simply drawing the just-displaced ink back from the printhead. The ink delivery system is typically designed with fluidic impedances that assure that liquid is preferentially drawn from the bag128instead of the printhead106. One pumping cycle is now complete.

The pumping process described above is now repeated continuously or from time-to-time, as required, under automatic control of the controller104such that ink is provided to the printhead106as needed to sustain normal printing operations. Thus, normal operation of the pump200can be described as reciprocations of the flexible diaphragm202between the distended condition and the collapsed condition.

These reciprocations, indicative of typical ink-moving operations of the pump200, are detected by a sensor214. In one embodiment, the sensor214is defined by an optical (light-beam) device that operates by way of a beam of light projected from an emitter across a span toward a detector. Normal operations of the pump200are detected as interruptions and restorations of the light beam while the actuator114reciprocates with the flexible diaphragm202. A corresponding signal is provided to the controller104as confirmation of normal ink pumping operations.

When the ink within the associated flexible bag128is depleted, a vacuum backpressure is communicated to the pump200. The flexible diaphragm202cannot reciprocate and so remains in its collapsed state. As such, the pump200fails to operate. When the actuator114is actuated, it immediately translates through its full stroke, stopping when it contacts the diaphragm in its collapsed state. This behavior is detected by the sensor214. As a result, the sensor214provides a corresponding signal that is interpreted by the controller104as an out-of-ink condition. The controller104then halts normal printing operations and provides one or more user notifications that the out-of-ink issue must be addressed by way of, for non-limiting example, indicating lights, e-mail messaging, etc.

It is important to note thatFIG. 2is typical of each color of ink used by the particular printer102. For purposes of illustration, the printer102is understood to consume four colors of ink as described above. Thus, a total of four connecting heads136—each having a pump200and a check valve138and being driven by an actuator114—would be used. Other printing systems having other numbers of connecting heads, pumps, check valves, actuators, sensors, etc., can also be configured and used in accordance with the present teachings.

First Illustrative Method

FIG. 3is a flow diagram depicting a method according to one embodiment of the invention. The method ofFIG. 3includes particular operations and order of execution. However, other methods including other operations, omitting one or more of the depicted operations, and/or proceeding in other orders of execution can also be used according to the present teachings. Thus, the method ofFIG. 3is illustrative and non-limiting in nature.

At300, a connecting head is manually coupled to an ink cartridge receiving port of an inkjet printer. The connecting head corresponds to a particular color of ink used by the printer (e.g., black, etc.). For purposes of non-limiting example, it is assumed that a connecting head136is coupled to a printer102by way of an ink cartridge receiving port118. In so doing, the connecting head136is also mated in fluid communication with a conduit112within the printer102.

At302, the connecting head is coupled to a supply of ink by way of a flexible liquid conduit (or tubing). The supply of ink is generally located remote from the printer. For purposes of the ongoing example, it is assumed that the connecting head136is coupled to a supply120having a flexible bag128by way of a hollow needle132and a fluid conduit134. Thus, the connecting head136is fluidly coupled to a remote supply of ink and is mechanically engaged in fluid communication with the printer102.

At304, a mechanical actuator of the printer applies one or more force pulses to a pump of the connecting head under automatic control. Under the ongoing example, it is assumed that an actuator114applies a series of force pulses to the flexible diaphragm202of the connecting head136in accordance with control signals from the controller104.

At306, ink flow from the remote supply to the printhead of the printer by way of the pump. For purposes of the ongoing illustration, it is assumed that black ink flows from the flexible bag128though the conduit134, into and out of the pump200, through the internal conduit112and to the pressure regulator108of the printhead106. Such ink flow is maintained until ceased under automatic operation of the controller104.

At308, the printer performs normal printing operations on media using the ink supplied from the remote supply (or source). For purposes of the ongoing example, it is assumed that text, images, etc., are formed on sheet media110by the printhead106using the ink provided by way of the connecting head136. Such imaging (normal print operations) are performed in accordance with signals provided by the controller104.

The foregoing method is illustrative of any number of methods contemplated by the present teachings. A remote supply of ink (with respect to a printer) is used for normal printing operations by way of a connecting head and its internal resources. As such, a relatively large quantity of ink can be supplied to a printer so as to proportionately increasing the time between replenishments relative to the use of ink cartridges that are supported (housed) substantially within the printer. Numerous other methods consistent with the operations and/or objectives of the present teachings can also be used.

Second Illustrative Method

FIG. 4is a flow diagram depicting a method according to one embodiment of the invention. The method ofFIG. 4includes particular operations and order of execution. However, other methods including other operations, omitting one or more of the depicted operations, and/or proceeding in other orders of execution can also be used according to the present teachings. Thus, the method ofFIG. 4is illustrative and non-limiting in nature.

At400, a printer performs normal printing operations by application of one or more colors of ink onto sheet media. For purposes of non-limiting illustration, it is assumed that the printer102is forming images on sheet media110in accordance with controller104signaling.

At402, reciprocations (normal operation) of the flexible diaphragm of an ink pump are detected by an optical sensor. In terms of the ongoing example, it is assumed that the sensor214detects normal operations of the flexible diaphragm202by way of motion of the actuator114.

At404, a flexible bag supplying ink to the printer runs out of ink, resulting in an internal vacuum backpressure communicated to the printer. For purposes of the ongoing example, the flexible bag128of the supply124is depleted of magenta ink, resulting in a vacuum backpressure being communicated to the corresponding pump200.

At406, the flexible diaphragm of the pump coupled to the depleted supply cannot reciprocate due to the vacuum backpressure. For purposes of the ongoing example, the flexible diaphragm202of the corresponding pump200is in an essentially motionless state, and cannot reciprocate despite force pulses applied by the actuator114and/or the urging of the spring206.

At408, the motionless state of the pump is detected by the corresponding sensor. For purposes of the ongoing example, it is assumed that the sensor214detects the substantially motionless state of the diaphragm202.

At410, the sensor signal indicating the motionless condition of the diaphragm is communicated to the controller and is interpreted as an out-of-ink condition. For purposes of the ongoing example, it is assumed that the sensor214signal sent to the controller104results in a user notification of the out-of-ink condition and/or halting of normal printing operations.