Abstract:
A print mechanism positioned in a housing having a pivotably mounted cover and including a ink flow regulator operatively connected to a print cartridge and provided with a plurality of seals to prevent contamination and damage from unwanted ink flow.

Description:
CROSS REFERENCE TO RELATED PATENT APPLICATION 
   This Application is related to and claims the benefit under 35USC 119(e) for the Provisional Patent Application of the same title having Ser. No. 60/798,936 filed on May 10, 2006. 

   FIELD OF THE INVENTION 
   This invention relates to ink jet printing. More specifically, the invention pertains to a system that uses an ink jet printing mechanism in conjunction with an ink supply mechanism and custom enclosure for the purpose of adapting existing ink jet printer technology for use in industrial printing applications. Such applications include but are not limited to the printing of bar codes, text or images on substrates such as paper, cardboard, ceramic tile, wood, concrete, plastic, metal, fabric and cloth. 
   BACKGROUND OF THE INVENTION 
   Ink Jet printing is a common method of non-impact printing. An ink jet printer emits intermittent streams of ink droplets from tiny nozzles in response to received electrical signals. The inventive device is applicable to all types of ink jet printers. 
   When used in industrial applications, conventional ink jet printers suffer from a variety of drawbacks and disadvantages. For example, when an ink jet print mechanism becomes damaged the printing process must be stopped until the print system can be restored to proper operational status. For ink jet print systems containing custom ink jet print mechanism an operator must stop an assembly line and physically disconnect the ink jet printer from its ink supply and mounting so that it can be removed for maintenance. This is a time consuming and often expensive process, both in terms of lost production stemming from a shut down line and the maintenance costs associated with servicing the ink jet print system. 
   Additionally, ink contamination of print media is a common a problem resulting from a damaged ink jet print mechanism or low ink condition. In the case of damaged ink jet print mechanism, improperly designed systems allow ink to leak from the print mechanism directly onto a print skid plate—the surface the print medium rests flush against during the printing process. This causes ink contamination: smearing and smudging on the print medium. Moreover, most ink jet printers must “pull” their ink from a regulator, such that the ink pressure in the ink jet print mechanism and corresponding feed line is less than atmospheric pressure (it is in a vacuum). This prevents ink from flowing freely out of the ink jet print mechanism. In print systems wherein the ink reservoir does not have a method of warning the operator of a low ink condition, the supply ink pressure may go below the pressure required by the pressure regulator to keep negative pressure in the ink jet print mechanism feed line. In the event that this happens, the remaining ink flows freely out of the ink jet print mechanism wherein it can contaminate the print medium, leak back into the print system, or in some cases both. 
   Industrial ink jet print applications require specialized high-volume ink delivery systems. To overcome the shortcomings of existing ink jet industrial print systems, a customized housing, ink delivery and regulation systems are provided. The first object of the present invention is to prevent failure of the inventive device through internal contamination by foreign bodies. A related object of the invention is to prevent electrical failure caused by ink contamination on the inside of inventive device. It is also an object of the invention to provide tool free access and maintenance for the purpose of quick replacement of key components, specifically those relating to ink delivery and ink jet printing. For that purpose, a related object is to use readily available modular components wherein the ink jet mechanism may be removed and replaced by an operator of average skill, independently of the other components and without tools. Another object of the invention is to provide a low ink warning mechanism for the purpose of preventing a low ink condition which may result in ink freely flowing out of the ink jet print mechanism. Related to this object, yet another object of the invention to prevent contamination of the print medium in the event of a low ink condition. An additional object of the invention is to provide a valve system in which an external ink supply can quickly be connected or disconnected without the use of specialized tools. Yet another object of the invention is to provide a drain path for ink such that ink leakage resulting from a damaged print mechanism, ink regulation system or a low ink condition will not cause ink contamination of the print medium. 
   SUMMARY OF THE INVENTION 
   It is to be understood that both the foregoing and general description and the following detailed description are exemplary, but are not restrictive, of the inventive device. In accordance with the principles and objectives of the invention, the inventive device includes a ink jet print mechanism, custom enclosure and ink supply control mechanisms. 
     FIG. 1  and  FIG. 2  represent the preferred embodiment of the inventive device  100 , an industrial print mechanism capable of printing text or graphics in 1 color up to ½″ in height. Inventive device  100  consists of a single print system  200  consisting of regulator  24 , print cartridge  34 , print stall  32  and gaskets  76 A and  76 B for the purpose of placing ½ inch of ink jet printing, consisting of text or characters in one color, on a print medium. The preferred embodiment utilizes a single print system for the simplicity of illustration, and not as a means of restriction. It is to be understood that alternate embodiments may include additional print systems  200  in one mechanical housing for the purpose of printing multiple colors, increasing the print height beyond the ½ inch a single print cartridge  34  can produce, or both. For example,  FIG. 6  demonstrates how assembly  600  utilizes four print systems  200  to generate a maximum print height of two inches. 
   Inventive device  100  consists of eight, main components: (1) a cover  72 , (2) a ink regulator system  24 , (3) a ½″ ink jet print cartridge  34 , (4) a print stall  32 , (5) two gaskets  76 A and  76 B, (6) a skid plate  78 , (7) a chassis  63 , (8) and two external mating points  59 . Cover  72  is made out of stainless steel and serves to protect the electronic and mechanical elements of the system from environmental debris and water spray. It is attached to chassis  63  on the end closest to print cartridge  34  such that it opens from one side allowing access to the inside of inventive device  100 . It secures to chassis  63  by way of a stainless steel latch, not shown, on the side opposite the pivot point. Part  70 , one-half of a magnetic switch, is attached to cover  72 , the second half, component  71  is attached to chassis  63 . The switch may be used to cut power to the system when the cover is opened or to perform other functions. 
   Regulator assembly  24 , which is secured to chassis  63 , changes the pressure of the supply of ink going to print cartridge  34  and monitors the pressure of the ink coming from an external reservoir, not shown. Regulator  24  consists of an aluminum sheet metal housing encloses a pressure regulator, and a pressure switch. The housing has an ink inlet and outlet utilizing parts of a quick-connect and disconnect nature. Unregulated supply ink enters the regulator assembly at atmospheric pressure. The regulator reduces the ink pressure such that it is supplied to the print cartridge at less than atmospheric pressure. A wire harness, not shown, accepts the input from magnetic cover switch halves  70  and  71  at the front of regulator assembly  24 . An external electrical connection to the magnetic switch is made at the back of regulator assembly  24 . 
   Ink flows from regulator  24  to ink jet print cartridge  34  via a flexible hose with quick connect ends. Print cartridge  34  sits in print stall  32  and can easily be removed without tools for replacement. Print stall  34  is permanently attached such that the face fits snugly up against the front of chassis  63 . Printing occurs through an opening in the front of chassis  63  in which the print mechanism portion of print cartridge  34  protrudes. 
   Gasket  76 B fits in a milled recess in the back of skid plate  78 . It prevents environmental contaminants from entering the system, and in the event the ink jet print mechanism is damaged or otherwise defective, the gasket prevents ink run-off from leaking into the system. 
   Skid plate  78  protects both the inventive device from misaligned print medium, e.g., boxes traveling down an assembly line, in addition, with the help of a guide rail installed on the opposite side of the assembly line, it aligns the print medium during printing operations. Skid plate  78  has a drip channel consisting of a vertical groove extending from the bottom center of the print area to the bottom of the skid plate. In the event of leaking ink from a damaged or defective print cartridge  34 , the drip channel serves as a path for unwanted ink such that the ink does not flow onto the face of the skid plate where it could cause ink contamination of the print medium. 
   Chassis  63  anchors all the components of the print system and it makes up the lower half of an enclosure. Electrical and supply ink connections are made at the back of chassis  63  and printing occurs at the front. 
   The inventive device may be attached to one or two external support members via four tapped holes in chassis  63 . Unused mounting holes may be covered with anodized aluminum plate  59 . 

   
     DESCRIPTION OF FIGURES 
       FIG. 1  A drawing containing an isometric view of inventive device  100 . 
       FIG. 2  A blown up isometric view of inventive device  100  and its sub assemblies. 
       FIG. 3  A cutaway side view of inventive device  100 &#39;s print sub assembly consisting of regulator  24 , print cartridge  34  and print stall  36 . 
       FIG. 4  contains isometric views of the front and back of skid plate  78  as well as a detailed view of the area in which the ink jet print mechanism portion of print cartridge  24  protrudes. 
       FIG. 5  shows print medium  307  moving down assembly line  301  in sequential steps:  300 ,  400  and  500  for the purpose of demonstrating how inventive device  100  operates during a typical printing operation. 
       FIG. 6  shows assembly  600 , an alternative embodiment of the present invention consisting of multiple print systems  200  combined in one housing. 
       FIG. 7  illustrates how multiple print cartridges  34  combine to form alternative embodiment  700 —an embodiment capable of producing two color text or graphics up to 1.5 inches in height. 
       FIG. 8  Alternative embodiment  800  consists of a configuration of print cartridges  34  arranged such they can produce print a maximum of three inches tall and consisting of one to three colors. 
   

   DETAILED DESCRIPTION OF THE INVENTION 
   For simplicity and illustrative purposes, the principles of the inventive device are described by referring mainly to an exemplary embodiment thereof, particularly with references to an example of the inventive device. However, one of ordinary skill in the art would readily recognize that the same principles are equally applicable to, and can be implemented in, any device designed to print in a similar manner. 
   Referring to all the drawings, it is to be understood that, according to common practice, the various components of the drawing may or may not be to scale. Reference numerals refer to components throughout the drawings. 
     FIG. 1  shows the preferred embodiment of the inventive device, inventive device  100 : an industrial ink jet print system capable of producing a half-inch of print height in one color. The preferred embodiment utilizes a single print system for the simplicity of illustration, and not as a means of restriction. It is to be understood that alternate embodiments may include additional print systems  200  in one mechanical housing for the purpose of printing more than one color and print height greater than the ½ inch of print a single print cartridge  34  can produce. For example,  FIG. 6  demonstrates how assembly  600  utilizes four print systems  200  to generate a maximum printing height of two inches. Alternate embodiments are discussed in detail further on. 
   As illustrated in  FIG. 2 , inventive device  100  consists of eight main components: cover  72 , ink regulator system  24 , ½″ ink jet print cartridge  34 , print stall  32 , two gaskets  76 A, not shown, and  76 B, skid plate  78 , chassis  63 , and two external mating points  59 . 
   The object of inventive device  100 , as it pertains to  FIG. 5  is to produce a half inch of print, consisting of text or graphics, on print medium. In the preferred embodiment the print medium is box  307 , as shown in  FIG. 5 , a typical product box, however, it is to be understood that inventive device  100  shall not be restricted to printing on boxes, and may be used to print on any medium capable of accepting the ink used in the ink-jet printing process. For the purpose of illustration, such mediums may include, but are not restricted to, paper, cardboard, ceramic tile, wood, concrete, plastic, metal, fabric and cloth. 
     FIG. 2  shows an exploded isometric view of inventive device  100 . Stainless steel cover  72 , is permanently attached to chassis  63  via two stainless steel 3/16″×⅛″ shoulder screws, not shown, and fastens to the back of the chassis using a stainless steel latch, also not shown. Cover  72  is designed to overlap the chassis in such a manner as to prevent environmental debris, such as airborne contaminants and dripping water, from entering inventive device  100 . Magnetic actuator  70 , one half of a magnetic switch, attaches to the inside of cover  72 . When cover  72  is closed, magnetic actuator  70  rests on top of magnetic sensor  71  resulting in a closed circuit on the magnetic switch. Magnetic switch state information may be used to cut power to inventive device  100  when cover  72  is opened, trigger a custom software driven operation, or all of the above. 
   All the components of inventive device  100  are rigidly attached to chassis  63 . Regulator assembly  24  attaches to the back of chassis  63  by four #6-32 screws, not shown. Print stall  32  rigidly attaches to the front of chassis  63  by four #4-40 screws, not shown, and utilizes gasket  76 A, which is not visible in this figure, but is shown in  FIG. 3 , to seal the gap between the front of print stall  32  and chassis  63 . A second gasket  76 B seals the gap between skid plate  78  and chassis  63 . The use of two gaskets:  76 A and  76 B, ensures that ink from a damaged or defective print cartridge  34  or regulator assembly  24  will not penetrate inventive device  100 , rather the ink will flow down milled drip channel  78 B of skid plate  78  as shown in  FIG. 4 . 
   Custom circuit board  42  takes input from an external controller, not shown, via high density  15  pin cable  73  made up of a cable consisting of seven individually shielded twisted wire pairs and both male and female high density  15  pin cable ends. High density  15  pin cable  73  mates to 15 pin DB-9M connection  43  at the back of circuit board  42 . Electrical input is routed such that 15 pin DB-9M connection  43  electrical input is transferred to a 14 pin ribbon cable, not shown, that mates to ribbon connector  44  the front of circuit board  42  on the inside of the inventive device  100 . The ribbon cable, not shown, transmits the electrical input from the external controller, not shown, to print stall  32 . 
     FIG. 3 , shows print sub assembly  200 , consisting of regulator assembly  24 , ½ inch ink jet print cartridge  34 , print stall  32  and two gaskets  76 A and  76 B. Note: regulator assembly  24  appears with various sheet metal components hidden for the purpose of illustrating the inner mechanics. Regulator assembly  24  consists of a sheet metal enclosure and integrated components. Supply ink, which comes from an external reservoir, not shown, that is located a minimum of 13″ above the center of male panel mount connector  7  and vented to atmospheric pressure, enters regulator assembly  24  through ⅛″ male panel mount connector  7  and travels through ⅛″ inner diameter flexible tubing  18 D to three-port manifold  16 . Three-port manifold  16  connects ink of common pressure to two separate mechanisms: pressure switch  15  and print pressure regulator  5 . The first of two exit ports on three-port manifold  16  connect the supply ink to pressure switch  15  via three flexible tubes  18 F,  18 G and  18 H, and two 90° tube elbows  17 D and  17 E. Pressure switch  15  has an integrated electrical switch capable of two states: open and closed. Pressure switch  15  is in an open state when the supply ink pressure is above ten inches of water. When the supply ink pressure drops below that level pressure switch  15  changes to a closed state. This information may be used by an external control device to cut power to inventive device  100 , send a signal to the equipment operator of a low ink condition, trigger a custom software driven action, or all of the above. 
   The second exit port on three-port manifold  16  feeds ink to print pressure regulator  5  via flexible tube  18 I, which connects to 90° tube elbow, not labeled, and then flexible tube  18 . Print pressure regulator  5  supplies ink to ½ inch ink jet print cartridge  34 , at less than atmospheric pressure for the purpose of preventing ink from freely flowing to print cartridge  34  when it is not in operation. Ink travels from pressure regulator  5  to jet print cartridge  34  via flexible tubes and connectors,  18 D,  17 C,  18 C,  18 B,  17 A,  18 A,  23 ,  35 , and  37 , respectively. Note that panel mount connector  23  rigidly attaches to regulator assembly  24  and that ⅛″ ID quick connector  35  is attached to ⅛″ flexible plastic tube  37 . 
   DB-9M connector  14  makes an electrical connection via wires, not shown, through regulator assembly  24  and mates with COMBICON, 3.81 mm, two-circuit plug  31 . Wires coming from magnetic sensor  63 , not shown, plug into the COMBICON, 3.81 mm, two-circuit plug  18 . Connection to an external device is made via DB-9M  14  connector. 
   Print cartridge  34  fits into the print stall  32  which is rigidly attached to the chassis  63 , as shown in  FIG. 2 . With further respect to  FIG. 3 , Gasket  76 A fits between print stall  32  and a face plate on the front of chassis  63 , not shown, to prevent ink from leaking back into inventive device  100  in the event of a damaged or defective print cartridge  34  or pressure regulator  5 . 
     FIG. 4 , shows isometric front and back views of skid plate  78 , an aluminum member used to align box  307  prior to and during the print process. As shown in  FIG. 5 , printing occurs in one direction, whereas inventive device  100  is positioned such that box  307 , transported an assembly line  301 , approaches the side of inventive device  100  defined by the large flap on skid plate  78  first. 
   The back of skid plate  78  contains a milled groove in which gasket  76 B, as shown in  FIG. 4  seals the gap between skid plate  78  and chassis  63 , for the purpose of preventing ink, water or other contaminants from entering inventive device  100 . In this respect, milled discharge groove  78 B in the front face of skid plate  78  allows ink from a damaged or defective print cartridge  34  to be dispelled without contacting the face of skid plate  78 . This prevents ink contamination of the print medium, such as box  307  in  FIG. 5 , in the event of a print system failure. 
     FIG. 5  demonstrates how inventive device  100  prints on box  307 . Note that  FIG. 5  is shown for illustrative purposes and thus inventive device  100  and assembly line  301  are shown without any structural supports and floating in space. In position  300  box  307  approaches inventive device  100  on assembly line  301 . Optical sensor  306  shoots beam of light  305  to reflector  304 . Beam of light  305  is broken by box  307  as it travels down assembly line  301 . Digital encoder  302  contains a wheel in direct contact with assembly line  301  for the purpose of determining the velocity of the assembly line, and by extension, box  307 . The velocity information of assembly line  301 , and the amount of time beam of light  305  is interrupted by box  307 , is used to determine the length of box  307  for the purpose of centering, or otherwise positioning, ink jet printing on box  307 . Rail  303  pushes box  307  against skid plate  78  during the printing process. In position  400 , inventive device  100  applies ink jet print on box  307 . In position  500 , box  307  has received print from inventive device  100  and continues down assembly line  301 . 
     FIG. 6  shows assembly  600 , an alternative embodiment of inventive device  100 . Whereas inventive device  100  is capable of producing ½ inch of print height, assembly  600  can produce two inches of print height by staggering multiple print cartridges  34  vertically. Assembly  600  contains four inkjet print cartridges  34 , not shown, that pass through openings:  801 ,  802 ,  803 , and  804 . The enclosure components of assembly  600  are the same as inventive device  100 —it has one chassis  63 , one cover  76 , and two external mating points  59 , however, assembly  600  incorporates four sub assemblies  200 , as shown in  FIG. 3  to produce two inches of print height. Print cartridges  34  pass through openings  801 ,  802 ,  803 , and  804  and are staggered such that, the bottom of print cartridge  34 , not shown, that protrudes through opening  802  occurs at the top of print cartridge  34 , also not shown, protruding through opening  801 , and so fourth. An external controller electronically links the four sub assembly  200  systems such that a print task is broken up and shared between multiple print cartridges  34  so that they, collectively, can produce one print image. 
     FIG. 7  shows alternate embodiment  700  of inventive device  100  wherein multiple print cartridges  34  are combined to produce multicolor print (text or graphics) on print medium  307 . Area  813  represents the face of the inventive device, as shown in  FIG. 6 . Printing  807  is shown to illustrate print, in this case the word “TEXT” applied to print medium  307  in the direction indicated by line  812 . Print faces  801 ,  802 ,  803 ,  804 ,  805  and  806  represent the faces of print cartridges  34  containing ink jet print nozzles. The print cartridges  34  are placed so that the tops and bottoms are coplanar, for example, the bottom of print face  802  aligns with the top of print face  801 . This is done so that there is no gap in printing between the top and bottom of two adjacent print cartridges  34 . The dot matrix in print face  801  represents an array of small ink jet nozzles which pulse ink on print medium  307  as dictated by and external controller, not shown. Ink jet nozzles apply ink by pulse firing tiny ink droplets, such as drops  810  and  811 , to form printing  807 . By stacking/staggering print faces  801 ,  802  and  803 , embodiment  700  can print up to 1.5 inches of print height on print medium  307 . By using one ink color in print cartridges  34  protruding through faces  801 ,  802  and  803 , and a different color ink in print cartridges  34  protruding through print faces  803 ,  804  and  805 , alternate embodiment  700  can perform two color printing operations. Additionally, more print cartridges  34  may be added in the fashion shown to print an unlimited number of colors. 
     FIG. 8  shows alternative embodiment  800  for the purpose of demonstrating how print cartridges  34  may be combined to produce three color print three inches in height. Area  813 B represents the face of the inventive device, as shown in  FIG. 6  Sub areas A, B and C each contain six print cartridges  34 . In area A, print faces  801  thru  806  combine to yield a print height of 3 inches. Additionally, areas A, B and C may be configured such that each area prints a different color. 
   The staggered print cartridge pattern shown in area A, B and C may be repeated in both the vertical and horizontal directions to create additional alternative embodiments of the inventive device. This method of staggering can be used to create print consisting of an unlimited number of colors and print height.