Abstract:
An ink cartridge has a cartridge body and an integrally molded lever. An angle, formed between the integrally molded lever and the cartridge body, is maintained at a minimum dimension by an angle size maintaining mechanism. The angle size maintaining mechanism enables remanufacturing of a used ink cartridge to reduce printer operating cost and reduce environmental waste.

Description:
BACKGROUND 
       [0001]    1. Field of the Disclosure 
         [0002]    The disclosed system generally relates to a lever for removably mounting one or more printer supply cartridges in a printer. In particular, this system relates to a latching mechanism for removably securing one or more ink cartridges in an inkjet printer. 
         [0003]    2. Description of the Related Art 
         [0004]    An inkjet printer typically includes one or more printheads and their corresponding ink cartridges. Each printhead includes an ink inlet that is connected to an ink cartridge and an array of drop ejectors, each ejector consisting of an ink pressurization chamber, an ejecting actuator and a nozzle through which droplets of ink are ejected. The ejecting actuator can be one of various types, including a heater that vaporizes some of the ink in the pressurization chamber to propel a droplet out of the orifice, or a piezoelectric device which changes the wall geometry of the chamber to generate a pressure wave that ejects a droplet. The droplets are typically directed toward paper or other recording medium to produce an image according to image data that is converted into electronic firing pulses for the drop ejectors as the recording medium is moved relative to the printhead. 
         [0005]    One common type of inkjet printer uses a replaceable ink cartridge which contains a cartridge body, a felt, and a supply of ink contained within the ink cartridge. The print cartridge is intended for single-use and, when the initial supply of ink is depleted, the ink cartridge is disposed of and a new ink cartridge is installed. However, frequent replacement of the print cartridge results in both a relatively high operating cost and increased environmental waste. 
         [0006]    Remanufacturers have overcome many challenges to enable re-use of ink cartridges, thereby reducing operating cost and environmental waste. An exemplary challenge is an ink cartridge having a lever and a latch having a spring element integrally molded into an ink cartridge. The latch, in combination with other features of the ink cartridge, provides positive engagement of the ink cartridge into an ink cartridge receiver. 
         [0007]    The lever, which is integrally molded, was designed for single-use thereby suffering from permanent deformation by the end of a single-use lifetime, resulting in a compromised engagement of the latch into the ink cartridge receiver. What is needed is an improvement to an ink cartridge having an integrally molded latch to enable use beyond a single-use life, including a latch which has suffered from permanent deformation. 
       SUMMARY 
       [0008]    The present system is directed to a replaceable ink cartridge having a cartridge body, an integrally molded lever a gap and angle having dimensions which separate the integrally molded lever from a front surface of a cartridge body. In preferred embodiments the cartridge body is modified to increase the gap and angle to maintain minimum dimensions capable of facilitating positive engagement into an ink cartridge receiver. In another aspect of preferred embodiments the cartridge body is modified by providing a flat spring capable of increasing the gap dimension. In yet another aspect of preferred embodiments the cartridge body is modified by configuring a compression spring to increase the gap dimension. 
         [0009]    Various objects, features, aspects, and advantages of the disclosure will become more apparent from the following detailed description of preferred embodiments of the disclosure, along with the accompanying drawings in which like numerals represent like components. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]      FIG. 1  is an isometric view of a prior art ink cartridge in new condition; 
           [0011]      FIG. 2   a  is a partial side view of an ink cartridge of  FIG. 1  at increased scale, showing a prior art ink cartridge in new condition, and including an engagement feature; 
           [0012]      FIG. 2   b  is a partial side view of the ink cartridge of  FIG. 1  at increased scale, showing a prior art ink cartridge at end-of-life condition, and includes an engagement feature; 
           [0013]      FIG. 3  is an isometric view, not to scale, of an ink cartridge at end-of-life condition having a formed feature; 
           [0014]      FIG. 4   a  is a partial side view taken from View B-B of  FIG. 3 , showing an ink cartridge having a formed feature; 
           [0015]      FIG. 4   b  is a partial side view taken from View B-B of  FIG. 3 , showing an ink cartridge having a formed feature, and having an applied force; 
           [0016]      FIGS. 5   a  through  5   e  are partial side views taken from View B-B of  FIG. 3  showing alternate embodiments. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    It is to be understood that various omissions and substitutions of equivalents are contemplated as circumstances may suggest or render expedient, but these are intended to cover the application or implementation without departing from the spirit or scope of the claims of the present disclosure. 
         [0018]      FIG. 1  shows a prior art ink cartridge in new condition (hereafter, “new ink cartridge  10   a ”). The new ink cartridge  10   a  is formed of various components, including injection molded plastic components assembled to contain ink (not shown). A cartridge body  15  includes a front surface  50 . The front surface  50  includes an upper portion  30 , a lower portion  35 , and an integrally molded lever  20 . The integrally molded lever  20  includes a fixed end  45  and a free end  40 . The integrally molded lever  20  further includes a latch  70  having a lock  75  and a ramp  80 . 
         [0019]      FIG. 2   a  shows a partial side view of the new ink cartridge  10   a  of  FIG. 1 . The new ink cartridge  10   a  has an integrally molded lever  20 , including latch  70  consisting of a lock  75  and ramp  80 . The integrally molded lever  20  is shown extended away at an angle  65   a  from the front surface  50  and toward an engagement tab  200 . 
         [0020]    The engagement tab  200  is part of an ink cartridge receiver (not shown). The ink cartridge receiver is installed within an inkjet printer (not shown) and includes features for positioning the new ink cartridge  10   a  in the inkjet printer. 
         [0021]    Integrally molded lever  20  is formed adjacent a front surface  50  of cartridge body  15 . The integrally molded lever  20  has a first side  25   a  and a second side  25   b.  A gap dimension  60   a  is formed between the front surface  50  and second side  25   b,  and an angle  65   a  is formed between the front surface  50  and second side  25   b  as shown in the Figure. The integrally molded lever  20  includes a spring force which is inherent to this plastic molded feature to facilitate installation of the new ink cartridge  10   a  into the ink cartridge receiver. For new ink cartridge  10   a,  the integrally molded lever  20 , having a gap dimension  60   a,  an angle  65   a,  and an effective spring rate, causes the integrally molded lever  20  to fully bias against engagement tab  200 . 
         [0022]      FIG. 2   b  shows the integrally molded lever  20  that is not biased into engagement tab  200 . This is a failure that commonly occurs for ink cartridges at end-of-life (hereafter “used ink cartridge  10   b ”) which are designed for single-use, resulting from the gap dimension  60   a  to decrease to a smaller dimension (as shown by  60   b ), the angle to be reduced to  65   b,  and to reduce the effective spring rate, with time due to creep. “Creep” is a common term in the plastics industry which describes the tendency of plastic to suffer permanent deformation due to mechanical stresses influenced by multiple installation cycles, increased time, temperature, mold design, gate location, and/or molding process parameters. 
         [0023]      FIG. 3  shows an improvement to the prior art used ink cartridge  10   a  of  FIG. 1 . An indention  100   a  is shown formed into the integrally molded lever  20 , resulting in formed protrusion  100   b  shaped into integrally molded lever  20  as shown in  FIGS. 4   a  and  4   b , and further described below. 
         [0024]      FIG. 4   a  shows a side view of  FIG. 3  taken from view B-B. The indention  100   a  is formed by using a press and die pair (not shown) designed specifically for this purpose. A die may be a plate shaped to support a second side  25   b  of integrally molded lever  20 , wherein the die has a recess or a hole. The press is a protrusion such as a punch shaped to form indention  100   a.  During forming, the press applies a force to a first side  25   a  of integrally molded lever  20 , supported by the die on the second side  25   b  of integrally molded lever  20 . Plastic is formed, resulting in indention  100   a,  with plastic yielding under force into the recess or hole in the die, shaping protrusion  100   b.  Protrusion  100   b  provides a stop to positively position the gap to an established minimum dimension, thereby increasing angle  65   b  to angle  65   c  and is about equivalent to angle  65   a.  Thus, protrusion  100   b  causes a gap (and resultant angle) having a dimension  60   c  which is greater than dimension  60   b  and about equivalent to dimension  60   a,  as shown in the Figure. The protrusion  100   b  provides a support to ensure a gap of a minimum dimension (about equivalent to gap dimension  60   a ) to enable latch  70  to more fully engage with engagement tab  200 . 
         [0025]      FIG. 4   b  shows  FIG. 4   a  with a minimum of callout numbers to provide clarity of the discussion to follow. A dimension H 1  defines the vertical distance from the intersection of the front surface  50  of cartridge body  15  and the fixed end  45  of integrally molded lever  20 , to the intersection of the latch  70  features lock  75  and ramp  80 . Dimension H 2  defines the vertical distance from the intersection of the front surface  50  of cartridge body  15  and the fixed end  45  of integrally molded lever  20 , to the center of protrusion  100   b.  In a preferred embodiment, protrusion  100   b  is formed having a vertical distance H 2  to be less than vertical distance H 1 . This preserves the original installation function of used ink cartridge  10   b  by enabling latch  70  to deflect away from engagement tab  200  to form a positive engagement between engagement tab  200  and lock  75  of latch  70 . This also preserves the original removal function of the used ink cartridge  10   b  by enabling a force F to be applied to the free end  40  of integrally molded lever  20 , enabling the lock  75  of latch  70  to disengage from engagement tab  200 , facilitating removal of the used ink cartridge  10   b  from the ink cartridge receiver (not shown). 
         [0026]    Alternate embodiments of the present disclosure are shown in  FIGS. 5   a  through  5   e,  showing side views as in  FIGS. 4   a  and  4   b , taken from View A-A of  FIG. 3 . In  FIG. 5   a , protrusion-2  102  is formed of a raised adhesive in the same vertical position as described in relation to  FIG. 4   a , and bonded to said integrally molded lever  20 . The adhesive should be of high viscosity and capable of adhering to the material of cartridge body  15  and at least partially hardening. A suitable adhesive includes, but is not limited to, 3M™ Scotch-Weld™ Hot Melt Adhesive 3738 TC. In  FIG. 5   b , there is protrusion-3  103  alternately positioned on the front surface  50  of cartridge body  15 , effectively providing the equivalent function as protrusion  100   b  or protrusion-2  102 . These embodiments demonstrate that a protrusion formed between the integrally molded lever  20  and the front surface  50  will increase the gap dimension by increasing the angle  65   c  and increase the effective spring rate of the integrally molded lever  20 . 
         [0027]      FIG. 5   c  shows a flat spring  104 , formed to essentially conform (in a V-shape) to the front surface  50  of cartridge body  15  and the second side  25   b  of integrally molded lever  20 . The flat spring  104  provides a force sufficient to increase the gap dimension from  60   b  to  60   c,  and the angle  65   b  to  65   c,  as with previous embodiments. The flat spring  104  is fixedly attached to at least one of the second side  25   b  and integrally molded lever  20 . The flat spring  104  may be adhesively bonded preferably with a soft thermoset elastomer capable shear flexing. 
         [0028]    An exemplary elastomer is a general purpose silicone adhesive such as MasterSil™ 711 from MasterBond®. Alternately, flat spring  104  may include mechanical features to bite into the mating plastic material (second side  25   b  and front surface  50 ), or other various commonly known attachment methods. Although not preferred, the flat spring  104  may be positioned in an inverted V-shape (not shown). The flat spring  104  may include bends, waves, or other similar geometry and while considered to those skilled in the art to be within the scope of a flat spring. 
         [0029]      FIG. 5   d  shows a coil spring  105  positioned above latch  70  near the free end  40  of integrally molded lever  20 . In contrast to the previous embodiments, a position above latch  70  will enable coil spring  105  to benefit from a longer overall length to maintain a flatter spring rate and reduce material fatigue. The coil spring  105  is fixedly attached to at least one end by one of the afore-referenced adhesives or by mechanical means. The coil spring provides a force sufficient to increase the gap dimension from  60   b  to  60   c,  and to increase the angle from  60   b  to  60   c.    
         [0030]      FIG. 5   e  shows an alternative protrusion to those shown in  FIGS. 4   a - b  and  FIGS. 5   a - b . Adhesive  106  is formed in a crevasse between the second side  25   b  and the front surface  50  of cartridge body  15 . A high viscosity soft thermoset elastomer will provide high adhesion and flexibility, such as the general purpose silicone adhesive previously referenced. In this embodiment, it is preferred to physically increase the gap to a dimension  60   c  prior to applying adhesive  106 , and to maintain this increased gap until the adhesive has cured. 
         [0031]    Yet another alternative is forming a protrusion by adhesively bonding a separate disk (not shown) or semi-sphere (not shown) to either the integrally molded lever  20  or front surface  50  of cartridge body  15 . It has also been contemplated that partial protrusions of any of the above embodiments may be employed, wherein the sum of the partial protrusions would result in a gap dimension  60   c  and angle  65   c.    
         [0032]      FIGS. 3-5   e , in addition to the alternatives described but not shown, disclose alternative gap size maintaining mechanisms capable of enabling an ink cartridge having an integrally molded latch to increase use beyond a single-use life, including a latch which has suffered from permanent deformation. 
         [0033]    The above referenced examples demonstrate the capability of increasing a gap dimension  60   b  to a gap dimension  60   c,  and angle  65   b  to  65   c,  to enable fully biased engagement of latch  70  into engagement tab  200 . Thus, a used ink cartridge  10   b  is capable of performing comparable to a new ink cartridge  10   a,  enabling use beyond a single-use life. 
         [0034]    Although the disclosure is taught with respect to used ink cartridges  10   b,  the practicalities of a remanufactured ink cartridge supply stream will inevitably result in new ink cartridges  10   a  being present with used ink cartridges  10   b.  The present disclosure is not only capable of implementation in single-use life ink cartridges, but may provide positive engagement of the ink cartridge into an ink cartridge receiver well beyond a single-use life. Therefore it is proper to generalize the present disclosure as applicable for all ink cartridges. 
         [0035]    It is contemplated, and will be clear to those skilled in the art that modifications and/or changes may be made to the embodiments of the disclosure. Accordingly, the foregoing description and the accompanying drawings are intended to be illustrative of the example embodiments only and not limiting thereto, in which the true spirit and scope of the present disclosure is determined by reference to the appended claims.