# Patent

## Title
Printer with gas bubble occlusion resistant conduits

## Abstract

An inkjet printer with a printhead and a conduit connected to the printhead. The conduit defines a flow path for the printing fluid and has an internal cross section configured such that the surface tension of printing fluid within it favors gas bubble growth along the conduit length over radial bubble growth that would fully occlude the flow path.

## Background
FIELD OF THE INVENTION
The present invention relates to inkjet printers and in particular, the fluidic system for supplying the printhead with ink.
CROSS REFERENCES TO RELATED APPLICATIONS
Various methods, systems and apparatus relating to the present invention are disclosed in the following US patents/patent applications filed by the applicant or assignee of the present invention:


















6,276,850
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12/017,331
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10/831,240
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11/124,176
11/124,188
11/124,170
11/124,187


11/124,189
11/124,190
11/124,180
11/124,193
11/124,183
11/124,178
11/124,177


11/124,148
11/124,168
11/124,167
11/124,179
11/124,169
11/187,976
11/188,011


11/188,014
11/482,979
11/735,490
11/853,018
11/944,450
12,023,815
12,035,414


11/228,540
11/228,500
11/228,501
11/228,530
11/228,490
11/228,531
11/228,504


11/228,533
11/228,502
11/228,507
11/228,482
11/228,505
11/228,497
11/228,487


11/228,529
11/228,484
11/228,489
11/228,518
11/228,536
11/228,496
11/228,488


11/228,506
11/228,516
11/228,526
11/228,539
11/228,538
11/228,524
11/228,523


11/228,519
11/228,528
11/228,527
11/228,525
11/228,520
11/228,498
11/228,511


11/228,522
11/228,515
11/228,537
11/228,534
11/228,491
11/228,499
11/228,509


11/228,492
11/228,493
11/228,510
11/228,508
11/228,512
11/228,514
11/228,494


11/228,495
11/228,486
11/228,481
11/228,477
11/228,485
11/228,483
11/228,521


11/228,517
11/228,532
11/228,513
11/228,503
11/228,480
11/228,535
11/228,478


11/228,479
12,035,419
6,238,115
6,386,535
6,398,344
6,612,240
6,752,549


6,805,049
6,971,313
6,899,480
6,860,664
6,925,935
6,966,636
7,024,995


7,284,852
6,926,455
7,056,038
6,869,172
7,021,843
6,988,845
6,964,533


6,981,809
7,284,822
7,258,067
7,322,757
7,222,941
7,284,925
7,278,795


7,249,904
11/737,726
11,772,240
11/863,246
11/863,145
11/865,650
6,087,638


6,340,222
6,041,600
6,299,300
6,067,797
6,286,935
6,044,646
6,382,769


6,787,051
6,938,990
11/242,916
11/144,799
11/198,235
11,861,282
11,861,284


11/766,052
7,152,972
11/592,996
D529952
6,390,605
6,322,195
6,612,110


6,480,089
6,460,778
6,305,788
6,426,014
6,364,453
6,457,795
6,315,399


6,338,548
7,040,736
6,938,992
6,994,425
6,863,379
6,540,319
6,994,421


6,984,019
7,008,043
6,997,544
6,328,431
6,991,310
10/965,772
7,140,723


6,328,425
6,982,184
7,267,423
7,134,741
7,066,577
7,152,945
7,303,689


7,021,744
6,991,320
7,155,911
11/107,799
6,595,624
7,152,943
7,125,103


7,328,971
7,290,857
7,285,437
7,229,151
11/330,058
7,237,873
11/329,163


11/442,180
11/450,431
7,213,907
6,417,757
11/482,951
11/545,566
11/583,826


11/604,315
11/604,323
11/643,845
11/706,950
11/730,399
11,749,121
11/753,549


11/834,630
11/935,389
11/869,670
7,095,309
11/945,157
11,957,473
11,967,235


12,017,896
6,854,825
6,623,106
6,672,707
6,575,561
6,817,700
6,588,885


7,075,677
6,428,139
6,575,549
6,846,692
6,425,971
7,063,993
6,383,833


6,955,414
6,412,908
6,746,105
6,953,236
6,412,904
7,128,388
6,398,343


6,652,071
6,793,323
6,659,590
6,676,245
7,201,460
6,464,332
6,659,593


6,478,406
6,978,613
6,439,693
6,502,306
6,966,111
6,863,369
6,428,142


6,874,868
6,390,591
6,799,828
6,896,358
7,018,016
10/296,534
6,328,417


6,322,194
6,382,779
6,629,745
6,565,193
6,609,786
6,609,787
6,439,908


6,684,503
6,843,551
6,764,166
6,561,617
10/510,092
6,557,970
6,546,628


10/510,098
6,652,074
6,820,968
7,175,260
6,682,174
7,303,262
6,648,453


6,834,932
6,682,176
6,998,062
6,767,077
7,278,717
6,755,509
10/534,813


6,692,108
10/534,811
6,672,709
7,303,263
7,086,718
10/534,881
6,672,710


10/534,812
6,669,334
7,322,686
7,152,958
7,281,782
6,824,246
7,264,336


6,669,333
10/534,815
6,820,967
7,306,326
6,736,489
7,264,335
6,719,406


7,222,943
7,188,419
7,168,166
6,974,209
7,086,719
6,974,210
7,195,338


7,252,775
7,101,025
11/474,281
11/485,258
11/706,304
11/706,324
11/706,326


11/706,321
11/772,239
11/782,598
11/829,941
11/852,991
11,852,986
11/936,062


11/934,027
11,955,028
12,034,578
12,036,908
11/763,440
11/763,442
11/246,687


11/246,718
7,322,681
11/246,686
11/246,703
11/246,691
11/246,711
11/246,690


11/246,712
11/246,717
11/246,709
11/246,700
11/246,701
11/246,702
11/246,668


11/246,697
11/246,698
11/246,699
11/246,675
11/246,674
11/246,667
11/829,957


11/829,960
11/829,961
11/829,962
11/829,963
11/829,966
11/829,967
11/829,968


11/829,969
11,946,839
11,946,838
11,946,837
11,951,230
7,156,508
7,159,972


7,083,271
7,165,834
7,080,894
7,201,469
7,090,336
7,156,489
10/760,233


10/760,246
7,083,257
7,258,422
7,255,423
7,219,980
10/760,253
10/760,255


10/760,209
7,118,192
10/760,194
7,322,672
7,077,505
7,198,354
7,077,504


10/760,189
7,198,355
10/760,232
7,322,676
7,152,959
7,213,906
7,178,901


7,222,938
7,108,353
7,104,629
11/446,227
11/454,904
11/472,345
11/474,273


7,261,401
11/474,279
11/482,939
7,328,972
7,322,673
7,306,324
7,306,325


11/603,824
11/601,756
11/601,672
7,303,261
11/653,253
11/706,328
11/706,299


11/706,965
11/737,080
11/737,041
11/778,062
11/778,566
11/782,593
11/934,018


11/945,157
11,951,095
11,951,828
11,954,906
11,954,949
11,967,226
7,303,930


11/246,672
11/246,673
11/246,683
11/246,682
60/939086
11,860,538
11,860,539


11/860,540
11,860,541
11,860,542
11/936,060
11,877,667
11,877,668
7,246,886


7,128,400
7,108,355
6,991,322
7,287,836
7,118,197
10/728,784
10/728,783


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
10/773,183
7,108,356


7,118,202
10/773,186
7,134,744
10/773,185
7,134,743
7,182,439
7,210,768


10/773,187
7,134,745
7,156,484
7,118,201
7,111,926
10/773,184
7,018,021


11/060,751
11/060,805
11/188,017
7,128,402
11/298,774
11/329,157
11/490,041


11/501,767
7,284,839
7,246,885
7,229,156
11/505,846
11/505,857
7,293,858


11/524,908
11/524,938
7,258,427
11/524,912
7,278,716
11/592,995
11/603,825


11/649,773
11/650,549
11/653,237
11/706,378
11/706,962
11,749,118
11/754,937


11,749,120
11/744,885
11/779,850
11/765,439
11/842,950
11/839,539
11/926,121


12,025,621
11/097,308
11/097,309
7,246,876
11/097,299
11/097,310
11/097,213


7,328,978
7,334,876
7,147,306
7,261,394
11/764,806
11/782,595
11,965,696


12/027,286
11/482,953
11/482,977
11/544,778
11/544,779
11/764,808
11/756,624


11/756,625
11/756,626
11/756,627
11/756,628
11/756,629
11/756,630
11/756,631


7,156,289
7,178,718
7,225,979
11/712,434
11/084,796
11/084,742
11/084,806


09/575,197
09/575,197
7,079,712
7,079,712
6,825,945
6,825,945
7,330,974


7,330,974
6,813,039
6,813,039
7,190,474
6,987,506
6,987,506
6,824,044


7,038,797
7,038,797
6,980,318
6,980,318
6,816,274
6,816,274
7,102,772


7,102,772
09/575,186
09/575,186
6,681,045
6,681,045
6,678,499
6,679,420


6,963,845
6,976,220
6,728,000
6,728,000
7,110,126
7,173,722
7,173,722


6,976,035
6,813,558
6,766,942
6,965,454
6,995,859
7,088,459
7,088,459


6,720,985
7,286,113
6,922,779
6,978,019
6,847,883
7,131,058
7,295,839


09/607,843
09/693,690
6,959,298
6,973,450
7,150,404
6,965,882
7,233,924


09/575,181
09/575,181
09/722,174
7,175,079
7,162,259
6,718,061
10/291,523


10/291,471
7,012,710
6,825,956
10/291,481
7,222,098
10/291,825
7,263,508


7,031,010
6,972,864
6,862,105
7,009,738
6,989,911
6,982,807
10/291,576


6,829,387
6,714,678
6,644,545
6,609,653
6,651,879
10/291,555
7,293,240


10/291,592
10/291,542
7,044,363
7,004,390
6,867,880
7,034,953
6,987,581


7,216,224
10/291,821
7,162,269
7,162,222
7,290,210
7,293,233
7,293,234


6,850,931
6,865,570
6,847,961
10/685,523
10/685,583
7,162,442
10/685,584


7,159,784
10/804,034
10/793,933
6,889,896
10/831,232
7,174,056
6,996,274


7,162,088
10/943,874
10/943,872
10/944,044
7,259,884
10/944,043
7,167,270


10/943,877
6,986,459
10/954,170
7,181,448
10/981,626
10/981,616
7,324,989


7,231,293
7,174,329
10/992,713
7,295,922
7,200,591
11/020,106
11/020,260


11/020,321
11/020,319
11/026,045
11/059,696
11/051,032
11/059,674
11/107,944


11/107,941
11/082,940
11/082,815
11/082,827
11/082,829
6,991,153
6,991,154


11/124,256
11/123,136
11/154,676
7,322,524
11/182,002
11/202,251
11/202,252


11/202,253
11/203,200
11/202,218
11/206,778
11/203,424
11/222,977
7,327,485


11/227,239
11/286,334
7,225,402
11/329,187
11/349,143
11/491,225
11/491,121


11/442,428
11/454,902
11/442,385
11/478,590
7,271,931
11/520,170
11/603,057


11/706,964
11/739,032
11,739,014
7,336,389
11/830,848
11/830,849
11/839,542


11/866,394
11/934,077
11,951,874
12,015,487
12,023,860
12,023,005
12,036,266


7,068,382
7,068,382
7,007,851
6,957,921
6,457,883
10/743,671
7,044,381


11/203,205
7,094,910
7,091,344
7,122,685
7,038,066
7,099,019
7,062,651


7,062,651
6,789,194
6,789,194
6,789,191
6,789,191
10/900,129
7,278,018


10/913,350
10/982,975
10/983,029
11/331,109
6,644,642
6,644,642
6,502,614


6,502,614
6,622,999
6,622,999
6,669,385
6,669,385
6,827,116
7,011,128


10/949,307
6,549,935
6,549,935
6,987,573
6,987,573
6,727,996
6,727,996


6,591,884
6,591,884
6,439,706
6,439,706
6,760,119
6,760,119
7,295,332


7,295,332
7,064,851
6,826,547
6,290,349
6,290,349
6,428,155
6,428,155


6,785,016
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


10/901,154
10/932,044
10/962,412
7,177,054
10/962,552
10/965,733
10/965,933


10/974,742
10/982,974
7,180,609
10/986,375
11/107,817
7,292,363
11/149,160


11/206,756
11/250,465
7,202,959
11/653,219
11/706,309
11/730,389
11/730,392


60/953443
11/866,387
60974077
6,982,798
6,870,966
6,870,966
6,822,639


6,822,639
6,474,888
6,627,870
6,724,374
6,788,982
7,263,270
6,788,293


6,946,672
6,737,591
6,737,591
7,091,960
09/693,514
6,792,165
7,105,753


6,795,593
6,980,704
6,768,821
7,132,612
7,041,916
6,797,895
7,015,901


7,289,882
7,148,644
10/778,056
10/778,058
10/778,060
10/778,059
10/778,063


10/778,062
10/778,061
10/778,057
7,096,199
7,286,887
10/917,467
10/917,466


7,324,859
7,218,978
7,245,294
7,277,085
7,187,370
10/917,436
10/943,856


10/919,379
7,019,319
10/943,878
10/943,849
7,043,096
7,148,499
11/144,840


11/155,556
11/155,557
11/193,481
11/193,435
11/193,482
11/193,479
7,336,267


11/281,671
11/298,474
7,245,760
11/488,832
11/495,814
11/495,823
11/495,822


11/495,821
11/495,820
11/653,242
11/754,370
60911260
11/829,936
11/839,494


11,866,305
11,866,313
11,866,324
11,866,336
11,866,348
11,866,359
11,970,951


12,036,264
7,055,739
7,055,739
7,233,320
7,233,320
6,830,196
6,830,196


6,832,717
6,832,717
7,182,247
7,120,853
7,082,562
6,843,420
10/291,718


6,789,731
7,057,608
6,766,944
6,766,945
7,289,103
10/291,559
7,299,969


7,264,173
10/409,864
7,108,192
10/537,159
7,111,791
7,077,333
6,983,878


10/786,631
7,134,598
10/893,372
6,929,186
6,994,264
7,017,826
7,014,123


7,134,601
7,150,396
10/971,146
7,017,823
7,025,276
7,284,701
7,080,780


11/074,802
7,334,739
11,749,158
11/842,948
12,015,477
12,025,746
12,025,747


12,025,748
12,025,749
12,025,750
12,025,751
12,025,754
12,025,756
12,025,757


12,025,759
12,025,760
12,025,761
12,025,762
12,025,764
12,025,765
12,025,766


12,025,767
12,025,768
10/492,169
10/492,152
10/492,168
10/492,161
7,308,148


10/502,575
10/531,229
10/683,151
10/531,733
10/683,040
10/510,391
10/919,260


10/510,392
10/778,090
11/944,404
11/936,638
12,031,615
6,957,768
6,957,768


09/575,172
09/575,172
7,170,499
7,170,499
7,106,888
7,106,888
7,123,239


7,123,239
6,982,701
6,982,703
7,227,527
6,786,397
6,947,027
6,975,299


7,139,431
7,048,178
7,118,025
6,839,053
7,015,900
7,010,147
7,133,557


6,914,593
10/291,546
6,938,826
7,278,566
7,123,245
6,992,662
7,190,346


11/074,800
11/074,782
11/074,777
11/075,917
7,221,781
11/102,843
7,213,756


11/188,016
7,180,507
7,263,225
7,287,688
11/737,094
11/753,570
11/782,596


11/865,711
12,036,904
11,856,061
11,856,062
11,856,064
11,856,066
11/672,522


11/672,950
11/672,947
11/672,891
11/672,954
11/672,533
11,754,310
11/754,321


11/754,320
11/754,319
11/754,318
11/754,317
11/754,316
11/754,315
11/754,314


11/754,313
11/754,312
11/754,311
12,015,507
12,015,508
12,015,509
12,015,510


12,015,511
12,015,512
12,015,513
6,593,166
7,132,679
6,940,088
7,119,357


7,307,272
6,755,513
6,974,204
6,409,323
7,055,930
6,281,912
6,893,109


6,604,810
6,824,242
6,318,920
7,210,867
6,488,422
6,655,786
6,457,810


6,485,135
6,796,731
6,904,678
6,641,253
7,125,106
6,786,658
7,097,273


6,824,245
7,222,947
6,918,649
6,860,581
6,929,351
7,063,404
6,969,150


7,004,652
6,871,938
6,905,194
6,846,059
6,997,626
7,303,256
7,029,098


6,966,625
7,114,794
7,207,646
7,077,496
7,284,831
11/072,529
7,152,938


7,182,434
7,182,430
7,306,317
7,032,993
7,325,905
11/155,545
11/144,813


7,172,266
7,258,430
7,128,392
7,210,866
7,306,322
11/505,933
11/540,727


11/635,480
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11/706,303
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11/782,589
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11/940,235
11,955,359
12,019,583
12,019,566


12,036,910
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7,287,831
11/875,936


12,017,818
6,804,030
6,807,315
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7,271,936
7,304,771


6,965,691
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11/338,783
11/603,823


11/650,536
12,025,633
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7,121,639


7,165,824
7,152,942
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7,096,137
7,302,592
7,278,034


7,188,282
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10/727,161
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10/727,227
10/727,160


10/934,720
7,171,323
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7,328,115


11,749,750
11,749,749
11,955,127
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6,795,215
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7,154,638
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6,398,332
6,394,573
6,622,923


6,747,760
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11/039,866
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6,986,560
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11/499,749
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11/743,661
11/743,659


11/743,655
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7,182,422
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7,281,330


10/854,503
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10/854,515
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7,281,777
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10/854,514
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7,266,661
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10/854,518
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11/735,881
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D541848
D528597
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7,274,485
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7,146,281
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11/293,823
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11/293,816
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7,201,468
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10/760,203
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12,043,708
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11/293,793
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11/688,863
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11/688,871
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12,014,770
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12,014,777
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12,014,784
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12,014,801
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12,014,804
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61,034,147
11/482,982
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11/482,984
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11,872,719


11,872,718
61033357
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D528156
10/760,180
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6,364,451
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7,125,098
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D536031
D531214
7,237,888
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6,944,970
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6,920,704
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10/760,241
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10/962,428
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7,163,287


7,258,415
7,322,677
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10/962,410
7,195,412
7,207,670
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7,220,072
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11/754,359
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11/223,262
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11/223,021
11/223,020


11/223,019
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D541849
29/279,123
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7,014,451
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6,759,723
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7,226,159
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7,063,408
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7,217,046
6,948,870
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6,988,789
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7,196,814
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7,025,434
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11/006,734
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7,128,386
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6,994,419
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7,289,156
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7,278,707
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7,018,025
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11/083,021
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11/084,757
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20060087544
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7,270,397
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7,311,257
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7,306,307
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11,766,043
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11,930,001
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7,021,746
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6,425,658
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6,464,325
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6,447,100
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6,803,989
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6,644,771
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7,284,843
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7,111,924
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6,536,874
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10/510,151
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6,672,706
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6,935,724
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7,084,951
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7,159,965
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7,216,957
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11/706,952
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11/778,572
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6,916,082
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6,979,075
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7,097,282
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7,194,629
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7,028,474
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7,207,656
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7,131,717
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11/202,217
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11/583,939
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11/749,149
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11,971,182
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6,878,564
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6,905,195
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7,033,008
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6,910,755
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7,134,740
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7,004,567
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7,001,008
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7,192,120
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7,014,298
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7,152,955
7,097,292
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7,152,944


7,147,303
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20060038853
11/248,832
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BACKGROUND OF THE INVENTION
The Applicant has developed a wide range of printers that employ pagewidth printheads instead of traditional reciprocating printhead designs. Pagewidth designs increase print speeds as the printhead does not traverse back and forth across the page to deposit a line of an image. The pagewidth printhead simply deposits 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.
Printing at these speeds consumes ink quickly and this gives rise to problems with supplying the printhead with enough ink. Not only are the flow rates higher but distributing the ink along the entire length of a pagewidth printhead is more complex than feeding ink to a relatively small reciprocating printhead.
The ink conduits can be blocked by air bubbles. Air bubbles can form in the ink conduits when dissolved gasses come out of solution during periods of inactivity. If the bubble is big enough, it can completely occlude the conduit and block the ink flow. The bubble can pin to the inside of the conduit such that it requires a finite force to be applied to move it, as if it had a static coefficient of friction. The bubble resists moving with the ink flow and can starve areas downstream of the bubble, or cause a detrimental pressure increase upstream of the bubble.
SUMMARY OF THE INVENTION
According to a first aspect, the present invention provides an inkjet printer comprising:
a printhead with an array of nozzles for ejecting printing fluid;
a conduit connected to the printhead, the conduit defining a flow path for the printing fluid; wherein,
the conduit has an internal cross section configured such that the surface tension of the printing fluid favors gas bubble growth along the conduit length over radial bubble growth that fully occludes the flow path.
The invention is predicated on the realization that the inherent tendency for surface tension to adopt the lowest energy configuration can be used make gas bubbles grow longitudinally in the ink line instead of radially. By preventing the bubble from growing across the entire flow path, it may constrict the flow but not form a blockage. Ink can still flow through the line without first having to overcome the resistance of a bubble surface tension pinned to the internal surface. Importantly, this allows the pressure on either side of the bubble to equalize during printer standby periods. A pressure build up in the printhead because of diurnal temperature changes can flood the nozzles.
Preferably the internal cross section has a first area and the second area adjoining the first area, the first area being defined as an area that will allow radial growth of the gas bubble until it is completely occluded, and second area being defined as an area that will resist radial intrusion of a gas bubble that completely occludes the first area. Preferably, the second area is shaped such that any gas bubble capable of expanding radially from the first area into the second area until the second area is void of printing fluid, would require an internal gas pressure greater than the internal gas pressure of gas bubbles formed in the printing fluid by outgassing.
Preferably, the internal cross section is star-shaped. Preferably, the internal cross section is triangular. Preferably, the internal cross section is ‘T’-shaped. Preferably, the internal cross section is cross-shaped. Preferably, the internal cross section is ‘three leaf clover’-shaped. In another preferred form, the internal cross section is “four leaf clover”-shaped.
According to a second aspect, the present invention provides an inkjet printer comprising:
a printhead with an array of nozzles for ejecting printing fluid;
a conduit connected to the printhead, the conduit defining a flow path for the printing fluid; wherein,
the conduit has an internal cross section configured such that its dimension in a first direction far exceeds its dimension in the second direction normal to the first direction such that the gas bubble growing within the conduit will break into smaller separate gas bubbles before the fluid includes the flow path because of Plateau-Rayleigh instability.
This aspect of the invention recognises that the phenomenon known as Plateau-Rayleigh instability (named after Joseph Plateau and Lord Rayleigh who investigated the phenomenon in 1873) can be used to ensure that a single gas bubble is not completely occlude the flow path defined by a conduit.
Preferably, the cross section of the conduit is an elongate rectangle. Optionally, the cross section of the printhead can have several intersecting, elongate rectangle sections. In another preferred form, the cross section of the conduit is annular such that the radial width of the conduit is far less than the circumference.
In a particularly preferred form, the printing fluid reservoir is a sump positioned at a lower elevation than the printhead, the sump having a headspace of air above the printing fluid, and an inlet located in the headspace, the conduit being connected to the inlet such that during printer standby periods, the printing fluid in the conduit hanging from the printhead creates negative hydrostatic pressure in the printhead.
The high print speeds require a large ink supply flow rate. This mass of ink is moving relatively quickly through the supply line. Abruptly ending a print job, or simply at the end of a printed page, means that this relatively high volume of ink that is flowing relatively quickly must also come to an immediate stop. However, suddenly arresting the ink momentum gives rise to a pressure pulse in the ink line. The components making up the printhead are typically stiff and provide almost no flex as the column of ink in the line is brought to rest. Without any compliance in the ink line, the pressure spike can exceed the Laplace pressure (the pressure provided by the surface tension of the ink at the nozzles openings to retain ink in the nozzle chambers) and flood the front surface of the printhead nozzles. If the nozzles flood, ink may not eject and artifacts appear in the printing.
The Applicant has addressed these issues by incorporating non-priming cavities into the printhead. A detailed description of the non-priming cavities is provided in the Applicant's co-pending U.S. Ser. No. 11/688,863, the contents of which is incorporated herein by reference. Briefly, the stiff structures that define the ink line have air pockets distributed long the length of the printhead. A pressure pulse in the ink will compress the air in the cavity as it passes that point in the ink line. Compressing the air in the cavity damps and dissipates the pressure pulse to avoid nozzle flooding.
During standby periods when the printer is not operating for an extended time, temperature variations cause the air in the non-priming cavities to expand and contract. The ‘hanging’ column of ink in the downstream line to the sump keeps the printhead at a negative pressure so air expansion does not cause ink to flood from the nozzles. However, a bubble occlusion in the downstream ink line can create a blockage strong enough to prevent the hanging column of ink from accommodating the air expansion during diurnal temperature variations. Instead, the expanding air pockets pump ink out of the nozzles. The resulting flood on the nozzle face can cause color mixing and must be rectified before printing can commence.
Using a conduit according to the present invention, prevents any outgassing bubbles from completely occluding the ink flow path. As the outgassing bubbles do not form a flow obstruction, there is no build up pressure on the upstream side of bubble. Any expansion of the air in the air pockets pumps ink into the sump instead of causing a nozzle flood. Furthermore, the hanging column of ink maintains the correct negative pressure at the nozzles.



BRIEF DESCRIPTION OF THE DRAWINGS
The invention will now be described by way of example only with reference to the preferred embodiments shown in the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a printer fluidic system;
FIGS. 2A and 2B are schematic transverse and longitudinal cross sections of a conduit during bubble nucleation;
FIGS. 3A and 3B are schematic transverse and longitudinal cross sections of the conduit showing maximum radial bubble growth;
FIG. 4 is a sketch of a star-shaped cross section conduit;
FIG. 5 is a sketch of a triangular cross section conduit;
FIG. 6 is a sketch of a T-shaped cross section conduit;
FIG. 7 is a sketch of a ‘three leaf clover’ cross section conduit;
FIG. 8 is a sketch of a ‘four leaf clover’ cross section conduit;
FIGS. 9A to 9C are sketches of bubble growth within a conduit according to a second aspect of the invention; and,
FIG. 10 is another embodiment of a conduit according to a second aspect of the present invention.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 is a schematic view of a prior art fluidic system of the type used in the above referenced U.S. Ser. No. 11/688,863. The operation of the system and its individual components are described in detail in U.S. Ser. No. 11/872,719 the contents of which are incorporated herein by reference.
Briefly, the printer fluidic system has a printhead assembly 2 supplied with ink from an ink tank 4 via an upstream ink line 8 and waste ink is drained to a sump 18 via a downstream ink line 16. The downstream ink line 16 has a shut off valve 14 which allows the fluidic system to purge the nozzles to correct colour mixing or recover clogged nozzles.
A single ink line is shown for simplicity. In reality, the printhead has multiple ink lines for full colour printing. The upstream ink line 8 has a shut off valve 10 for selectively isolating the printhead assembly 2 from the pump 12 and or the ink tank 4. The pump 12 is used to actively prime or flood the printhead assembly 2. The pump 12 is also used to establish a negative pressure in the ink tank 4. During printing, the negative pressure is maintained by the bubble point regulator 6.
The printhead assembly 2 is an LCP (liquid crystal polymer) molding 20 supporting a series of printhead ICs 30 secured with an adhesive die attach film (not shown). The printhead ICs 30 have an array of ink ejection nozzles for ejecting drops of ink onto the passing media substrate 22. The nozzles are MEMS (micro electromechanical) structures printing at true 1600 dpi resolution (that is, a nozzle pitch of 1600 npi), or greater. The fabrication and structure of suitable printhead IC's 30 are described in detail in U.S. Ser. No. 11/246,687 the contents of which are incorporated by reference. The LCP molding 20 has a main channel 24 extending between the inlet 36 and the outlet 38. The main channel 24 feeds a series of fine channels 28 extending to the underside of the LCP molding 20. The fine channels 28 supply ink to the printhead ICs 30 through laser ablated holes in the die attach film.
Above the main channel 24 is a series of non-priming air cavities 26. These cavities 26 are designed to trap a pocket of air during printhead priming. The air pockets give the system some compliance to absorb and damp pressure spikes or hydraulic shocks in the ink. The printers are high speed pagewidth printers with a large number of nozzles firing rapidly. This consumes ink at a fast rate and suddenly ending a print job, or even just the end of a page, means that a column of ink moving towards (and through) the printhead assembly 2 must be brought to rest almost instantaneously. Without the compliance provided by the air cavities 26, the momentum of the ink would flood the nozzles in the printhead ICs 30. Furthermore, the subsequent ‘reflected wave’ can generate a negative pressure strong enough to deprime the nozzles.
As discussed above, temperature variations cause the air in the non-priming cavities to expand and contract. This can be problematic during standby periods when the printer is not operating for an extended time. The ‘hanging’ column of ink in the downstream line 16 to the sump 18 keeps the printhead 2 at a negative pressure so air expansion does not cause ink to flood from the nozzles 30. However, a bubble occlusion in the downstream ink line 16 can create a blockage strong enough to prevent the hanging column of ink from accommodating the air expansion during diurnal temperature variations. Instead, the expanding air pockets pump ink out of the nozzles. The resulting flood on the nozzle face can cause color mixing and must be rectified before printing can commence.
This can be rectified using a conduit according to the present invention of the downstream ink line 16. FIGS. 2A and 2B are sketches of the transverse and longitudinal cross sections of the conduit 16. The cross section of the conduit 16 has two areas—the first area 42 and a second area 44. Both the first and second areas 42 and 44 defining a flow path for the ink 50. Outgassing bubble 40 nucleates on the side of the first area 42 and expands radially and longitudinally.
In FIGS. 3A and 3B, the outgassing bubble 40 has grown to completely occlude the first area 42. However the second area 44 remains filled with ink 50. The shape of the outgassing bubble 40 is defined by the radius Rtube of the first area 42 and the maximum possible radius Rmax at the unconstrained face 46 of the bubble 40. The unconstrained face 46 of the bubble 40 will naturally tend towards the lowest energy state. Accordingly the radius of curvature Rmax of the unconstrained face 46 will be the maximum that the gas pressure within the bubble 40 will allow (which corresponds to the minimum surface area that the bubble face 46 can have at the gas pressure). With increasing gas pressure, the radius of the bubble face 46 reduces, and the surface area of the bubble face 46 increases.
In order for the bubble 40 to continue growing into the second area 44 and eventually occluding it, the gas pressure within the bubble 40 would need to be enough to form a semicircular bubble surface 48 having a critical radius of curvature Rcrit. Knowing the internal gas pressure of outgassing bubbles 40, the first area 42 and the second area 44 can adjoin each other such a way that Rmax of any bubble surface 46 formed during the expected range of ambient conditions is greater than Rcrit. This will prevent any bubble 40 nucleating is the first area 42 from continuing to grow radially into the second area 44. Instead further bubble roof will be in the longitudinal direction of the first area 42 (see FIG. 3B). In this way the ink 50 always has a flow path around the bubble 40.
The ordinary worker will appreciate that the second area 44 can also the configured such that an outgassing bubble 40 nucleating on its inner wall will never grow large enough to occlude the first area 42. Furthermore, once the printer has come out of standby mode as strong flow of ink from the printhead assembly 2 (see FIG. 1) to the sump 18 will clear the downstream ink line 16 of the outgassing bubbles 40.
FIGS. 4 to 8 are sketches of possible cross sections of the conduit 16. FIG. 4 shows a star-shaped cross section with a central for defining the first area 42 while the points of the star provide a plurality of second areas 44. An outgassing bubble 40 in the first area 42 will not continue to grow radially into the points 44. Instead, further bubble growth will be longitudinal. In this embodiment, if the outgassing bubble 40 nucleates in one of the points 44 of the star, then bubble growth may extend further into that point than any of the others. However, the remainder of the points will provide a flow path for the ink 50.
Similarly, the triangular cross section shown in FIG. 5 will contain any outgassing bubbles 40 in a central area 42 while vertices 44 of the triangle remains filled with ink 50. In figure six, the cross section is T-shaped. Bubble 40 growth and occlusion in one section 42 of the ‘T’ will not extend into the other section 44 of the ‘T’.
FIGS. 7 and 8 show cross sections having a three leaf and four leaf clover shape respectively. These cross sections are particularly useful when applied to extruded, flexible tubing. Not only do the leafs 44 have a relatively large surface area to provide little resistance to any flow of ink 50 when central bore 42 is occluded by a bubble 40, but the clover shape is resistant to kinking in a way that blocks all fluid flow.
FIGS. 9A, 9B and 9C show the cross sections of conduit 16 according to the second aspect of the invention. These cross sections extend into one dimension X for more than the transverse dimension Y. If an outgassing bubble 40 nucleates in conduit 16 it will grow as a single bubble 40 in the X direction. However before the bubble 40 can extend completely across the conduit 16, a phenomenon known as the Plateau Rayleigh instability will cause the bubble 40 to break up into separate bubbles 52, 54 and 56 (the FIG. 9C). This will ensure that the cross sections is never completely occluded and the ink 50 has flow path between an around the individual bubbles.
Optionally, FIG. 10 shows the cross section of an annular conduit 16. The circumference X of the annulus is far greater than the width Y of the annual flow path. Once again, any single outgassing bubbles will eventually become unstable and split into individual bubbles 52, 54 and 56. Between these bubbles, the ink 50 maintains a flow path.
The present invention has been described herein by way of example only. Skilled workers in this field will readily recognise many variations and modifications which do not depart from the spirit and scope of the broad inventive concept.

## Claims

1. An inkjet printer comprising:
an ink channel connected at first end to an ink supply and connected at a second, opposite, end to a sump;
a printhead engaged with the ink channel between the first end and the second end of the ink channel, the printhead configured to receive ink from the ink channel as the ink propagates from the first end of the ink channel to the second end of the ink channel; and
a conduit connecting the ink channel to the ink sump, the conduit establishing a negative hydrostatic pressure in the printhead, wherein
an internal cross section of the conduit, along substantially an entire length thereof, is shaped to encourage gas bubble growth in a direction and form that substantially prevents full occlusion of any portion of the conduit by the gas bubble.

2. An inkjet printer according to claim 1, wherein the internal cross section has a first area and a second area adjoining the first area, the first area being an area allowing radial growth of the gas bubble to a point of full occlusion of the first area, and the second area being an area resisting radial intrusion of the gas bubble from the first area into the second area.

3. An inkjet printer according to claim 2, wherein the second area is shaped relative to the first area such that a gas bubble capable of expanding radially from the first area into the second area to fully occlude the second area, would require an internal gas pressure greater than an internal gas pressure of gas bubbles formed in the printing fluid by outgassing.

4. An inkjet printer according to claim 1 wherein the internal cross section is star-shaped.

5. An inkjet printer according to claim 1 wherein the internal cross section is triangular.

6. An inkjet printer according to claim 1 wherein the internal cross section is ‘T’-shaped.

7. An inkjet printer according to claim 1 wherein the internal cross section is cross-shaped.

8. An inkjet printer according to claim 1 wherein the internal cross section is ‘three leaf clover’-shaped.

9. An inkjet printer according to claim 1 wherein the internal cross section is “four leaf clover”-shaped.

10. An inkjet printer according to claim 1 wherein
the sump is positioned at a lower elevation than the printhead and defines a headspace of air above the printing fluid, the sump further including an inlet located in the headspace, and
the conduit is connected to the inlet to allow the printing fluid in the conduit to hang with respect to the printhead and thereby establish the negative hydrostatic pressure in the printhead.