Patent Publication Number: US-7712883-B2

Title: Print cartridge body

Description:
BACKGROUND 
   Multicolored ink-jet cartridges usually include a body having a plurality of ink reservoirs, each for containing different colored ink, and a print head having a print head die with a plurality of slots communicatively coupled to the plurality of ink reservoirs via an ink-delivery manifold. Ink-delivery manifolds increase the size of ink-jet cartridges. This is a problem, especially for applications involving ink-jet cartridges having smaller form factors. Ink delivery manifolds may increase the number and complexity of the process steps used to manufacture ink-j et cartridges and thus the cost of the ink-jet cartridges. Moreover, the body of some ink-jet cartridges is formed as a one-piece injection-molded part and may involve using one or more mold-slide inserts for forming channels in an ink-delivery manifold. Each mold-slide insert leaves behind one or more openings (or mold-slide-insert access holes) in the cartridge body. One or more plugs subsequently seal each mold-slide-insert access hole. The use of a plug and mold-slide-inserts can be costly from a manufacturing standpoint. 

   
     DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a three-dimensional representation of an embodiment of a print cartridge, according to an embodiment of the present invention. 
       FIG. 2  is a three-dimensional representation of an embodiment of a print cartridge, viewed from the bottom, according to another embodiment of the present invention. 
       FIG. 3  is a three-dimensional representation of an embodiment of a cartridge body, according to another embodiment of the present invention. 
       FIG. 4  is a top view of an embodiment of a cartridge body, according to another embodiment of the present invention. 
       FIG. 5  is a bottom view of an embodiment of a cartridge body, according to another embodiment of the present invention. 
       FIGS. 6 ,  7 , and  8  are cross-sectional views respectively taken along lines  6 - 6 ,  7 - 7 , and  8 - 8  of  FIG. 5 , according to another embodiment of the present invention. 
       FIG. 9  is a three-dimensional representation of an embodiment of a single-colored print cartridge, according to another embodiment of the present invention. 
       FIG. 10  is a three-dimensional representation of an embodiment of a single-colored print cartridge, viewed from the bottom, according to another embodiment of the present invention. 
       FIG. 11  is a top view of an embodiment of a cartridge body, according to another embodiment of the present invention. 
       FIG. 12  is a bottom view of an embodiment of a cartridge body, according to another embodiment of the present invention. 
       FIG. 13  is a cross-sectional view taken along line  13 - 13  of  FIG. 12 , according to another embodiment of the present invention. 
       FIG. 14  is a top view of an embodiment of a single-color, two-compartment cartridge body, according to another embodiment of the present invention. 
   

   DETAILED DESCRIPTION 
   In the following detailed description of the present embodiments, reference is made to the accompanying drawings that form a part hereof, and in which are shown by way of illustration specific embodiments that may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice disclosed subject matter, and it is to be understood that other embodiments may be utilized and that process, electrical or mechanical changes may be made without departing from the scope of the claimed subject matter. The following detailed description is, therefore, not to be taken in a limiting sense, and the scope of the claimed subject matter is defined only by the appended claims and equivalents thereof. 
     FIG. 1  is a three-dimensional representation of a print (or ink-jet) cartridge  100 , according to an embodiment. For one embodiment, ink-jet cartridge  100  may be a multi-colored, e.g., two or more colors, or a single-colored, e.g., black, ink-jet cartridge. For another embodiment, ink-jet cartridge  100  may be used in various imaging devices, such as facsimile machines, desktop printers, manual hand-held printers, etc. Ink-jet cartridge  100  includes a cartridge body  102 . A head assembly  104 , such as a Tab-Head-Assembly (THA), is attached to cartridge body  102 . For one embodiment, head assembly  104  includes flexible circuit and a print head die with an orifice plate (not shown in  FIG. 1 ), as is known by those of skill in the art. Head assembly  104  includes a plurality of interconnect pads  105  for coupling the flexible circuit to a printer controller. A cover  106  closes one or more ink compartments formed in body  102 . For one embodiment, one or more vent channels are formed in cover  106  that communicate with the ink compartments, as is known in the art. For another embodiment, a vent label  108  is adhered to cover  106  and overlies at least a portion of the vent channels. 
   For one embodiment, alignment lugs  109  are optionally formed on cartridge body  102  to facilitate installation in a printer. For another embodiment, elimination of alignment lugs  109  eliminates a need for using a front mold slide during manufacture. For another embodiment, zero draft surfaces  110  are formed in cartridge body  102  and are used for assembly registration to tooling and alignment in a printer. For another embodiment, a plurality of legs  120  extends from a bottom of cartridge body  102 . Legs  120  provide clearance between the bottom cartridge body  102  and a surface on which ink-jet cartridge  100  may be located for protecting the print head die located at the bottom of cartridge body  102 . Alternatively, legs  120  may be unitary structures, such as ribs extending from the bottom of cartridge body  102 . 
     FIG. 2  is a three-dimensional representation of ink-jet cartridge  100 , viewed from the bottom, according to another embodiment. The ink-jet cartridge  100  of  FIG. 2  is configured as a multi-colored ink-jet cartridge, e.g., a tri-colored ink-jet cartridge. Head assembly  104  includes a print head die  210  with the orifice plate removed. An encapsulant  212  encapsulates a plurality of electrical interconnects that interconnect the flexible circuit of head assembly  104  to electrical contacts of print head die  210 . For one embodiment, the electrical contacts of print head die  210  selectively supply electrical power to a plurality of resistors or piezoelectric devices that are used to expel ink from print head die  210 . A plurality of slots  220  is formed in print head die  210 . Slots  220  are communicatively (or fluidly) coupled to the ink compartments within cartridge body  102  and receive ink from the ink compartments and deliver it to orifices in the orifice plate. 
   Note that the bottom of ink-jet cartridge  100  is substantially one plane and is not stepped as is common for many conventional ink-jet cartridges. That is, ink-jet cartridge  100  has a substantially rectangular (or square for some embodiments) profile when viewed along a direction parallel to a scanning direction (indicated by arrows  250  in  FIGS. 1 and 2 ) of ink-jet cartridge  100  during printing. This acts to reduce the complexity of the ink-delivery channels for delivering ink to print head die  210  and to eliminate the need for an ink-delivery manifold and thereby acts to reduce manufacturing time and thus costs. In addition, the bottom of ink-jet cartridge  100  being substantially one plane provides for a longer print head die, in a direction perpendicular to scanning direction  250 , relative to a length of the ink-jet cartridge in the direction perpendicular to scanning direction  250 , thus enabling a longer print swath. 
     FIG. 3  is a three-dimensional representation of a cartridge body  300 , e.g., that can be used as the cartridge body of ink-jet cartridge  100  of  FIGS. 1 and 2 , according to another embodiment. Common reference numbers denote similar elements in  FIGS. 1-3 . For one embodiment, cartridge body  300  includes a plurality of compartments  310  for containing different colored inks, such as red, blue, and green, magenta, yellow, and cyan, etc. Partitions  312  are disposed in the interior of cartridge body  300  to separate compartments  310  from each other, and thereby form compartments  310 . For one embodiment, compartments  310  have substantially equal volumes. 
     FIG. 4  is a top view of a cartridge body, such as cartridge body  102  of  FIGS. 1 and 2  or cartridge body  300  of  FIG. 3 , according to another embodiment. The cartridge body includes a plurality of compartments  410  for containing different colored inks. Outlet ports  4201 - 4203  are respectively formed at the bottoms of compartments  4101 - 4103 . Note that compartments  410  are in series along a direction perpendicular to the scanning direction  250 . Alternatively, partitions  412  disposed in an interior of the cartridge body and that separate compartments  410  from each other are substantially parallel to the scanning direction  250 . For one embodiment, a capillary medium, such as foam, may be disposed in each of compartments  410  for exerting a capillary force on the ink that acts to prevent the ink from leaking. Alternatively, other suitable backpressure generating mechanisms may be used in the cartridge, such as free-ink spring-bag, bellows systems, etc., to prevent the ink from leaking. 
     FIG. 5  is a bottom view of the cartridge body of  FIG. 4 , according to another embodiment. Common reference numbers denote similar elements in  FIGS. 1-3  and  FIG. 5 . The cartridge body includes a plurality of ink-feed channels  520  that are communicatively coupled to outlet ports  420 . In other words, outlet ports  420  open into ink-feed channels  520 . Ink-feed channels  520  open directly to an exterior of the cartridge body and communicatively couple compartments  410  to the exterior of the cartridge body. Ink-feed channels  520  are configured to respectively align with slots in the print head die, such as slots  220  of print head die  210  of  FIG. 2 , for delivering ink thereto. For one embodiment, portions of the bottom of the cartridge body surrounding ink-feed channels  520  are attached directly to portions of the print head die that surround the slots of the print head die, e.g., using an adhesive or encapsulant. For example, the portions of the bottom of the cartridge body surrounding ink-feed channels  520  may be attached directly to portions of print head die  210  of  FIG. 2  that surround slots  220  of print head die  210  on a side opposite to that shown in  FIG. 2 . In operation, ink flows from compartments  410  ( FIG. 4 ), through outlet ports  420  ( FIGS. 4 and 5 ), into ink-feed channels  520  ( FIG. 5 ), and subsequently into slots  220  of print head die  210  ( FIG. 2 ), for example. It should be noted that although generally square or rectangular outlet ports  420  are shown, they could be other shapes such as circles, slots, etc. Additionally, ink-feed channels  520  could be other shapes, sizes or eliminated altogether. For embodiments where ink-feed channels  520  are eliminated, outlet ports  420  open directly into slots of a print head die, such as slots  220  of print head die  210  ( FIG. 2 ). 
   For one embodiment, a ratio of the length L C  ( FIG. 5 ) of the cartridge body perpendicular to the scanning direction  250  to a length L S  of ink-feed channels  520  and/or a length of slots of a print head die, such as slots  220  of print head die  210  ( FIG. 2 ) perpendicular to the scanning direction  250  is less than about 2. In other words, length L S  of ink-feed channels  520  and/or of the slots  220  of print head die  210  are greater than about ½ the length L C  of the cartridge body. The ratio of the length of a conventional cartridge body perpendicular to its scanning direction to a length of ink-feed channels of the conventional cartridge body or the slots of a print head die coupled to a conventional cartridge body is greater than about 3. In other words, the ink-feed slots in the die and/or channels of conventional cartridge bodies are typically less than about ⅓ of the length of the cartridge body. A ratio of the length L C  of the cartridge body to the length L S  of ink-feed channels  520  less than about 2 eliminates the need for an ink-delivery manifold and thereby acts to reduce manufacturing time and the part count and thus costs. 
     FIGS. 6 ,  7 , and  8  are cross-sectional views respectively taken along lines  6 - 6 ,  7 - 7 , and  8 - 8  of  FIG. 5 , according to another embodiment. In one embodiment, a duct (or standpipe)  620  (see also  FIG. 4 ) is located within each compartment  410  and is connected (or opens) to an outlet port  420 , as shown in  FIGS. 6 ,  7 , and  8 . Outlet ports  420  open into ink-feed channels  520 . For another embodiment, a filter may be located over an inlet  625  ( FIGS. 6 ,  7 , and  8 ) of each of ducts  620 . For one embodiment, the capillary material overlies the filter. 
   Arrows  650  ( FIG. 6 ) illustrate a flow path of ink from compartment  410   1  through duct  620   1 , through outlet port  420   1 , and into ink-feed channel  520   1 . Note that ink-feed channel  520   1  acts as a channel expansion, and the ink-flow expands as it passes substantially vertically downward through outlet port  420   1  and into ink-feed channel  520   1 . As the ink-flow expands to fill ink-feed channel  520   1 , it flows substantially horizontally and substantially perpendicular to the scanning direction, which is perpendicular to the plane of  FIG. 6 . 
   Arrows  750  ( FIG. 7 ) illustrate a flow path of ink from compartment  410   2  through duct  620   2 , through outlet port  420   2 , and into ink-feed channel  520   2 . Note that ink-feed channel  520   2  acts as a channel expansion, and the ink-flow expands as it passes substantially vertically downward through outlet port  420   2  and into ink-feed channel  520   2 . As the ink-flow expands to fill ink-feed channel  520   1 , it bifurcates and flows in opposite directions, each substantially horizontally and substantially perpendicular to the scanning direction, which is perpendicular to the plane of  FIG. 7 . 
   Arrows  850  ( FIG. 8 ) illustrate a flow path of ink from compartment  410   3  through duct  620   3 , through outlet port  420   3 , and into ink-feed channel  520   3 . The ink-flow exits outlet port  420   3  parallel to a normal to a plane of outlet port  420   3  at an angle to the vertical, and thus at outlet port  420   3 , the ink-flow and the normal to the plane of outlet port  420   3  has a vertically downward directed component and a horizontal component substantially perpendicular to the scanning direction, which is perpendicular to the plane of  FIG. 8 . After exiting outlet port  420   3 , the ink-flow flows substantially horizontally and substantially perpendicular to the scanning direction to fill ink-feed channel  520   3 . 
   With reference to  FIGS. 5 and 6 , it is seen that for one embodiment, outlet port  420   1  may extend over a portion of the length of ink-feed channel  520   1  in a direction perpendicular to scanning direction  250 , starting at an end  540  of ink-feed channel  520   1 .  FIGS. 5 and 8  illustrate that a portion of outlet port  420   3  may extend past an end  542  of ink-feed channel  520   3 , and a remaining portion may extend into ink-feed channel  520   3 .  FIGS. 5 and 7  illustrate that outlet port  420   2  may be located away from ends  544  of ink-feed channel  520   2 . 
   Note that the cartridge body of  FIGS. 4-8  and ink-feed channels  520  thereof are formed as single-piece and form a unitary structure. Attaching a print head nozzle array, such as print head die  210  of  FIG. 2 , seals ink-feed channels  520  to the corresponding slots  220  in the print head die. 
     FIG. 9  is a three-dimensional representation of a single-colored, e.g., black, print (or ink-jet) cartridge  900 , according to another embodiment. Ink-jet cartridge  900  includes a cartridge body  902 . Common reference numbers denote similar elements in  FIGS. 1 and 2  and  FIG. 9 . Cartridge body  902  includes a single compartment  910  for containing ink. For one embodiment, the cover  106  of the ink-jet cartridge  100  of  FIG. 1  may be used to close compartment  910 . This means that for some embodiments cover  106  can be used for both the three-compartment cartridge body  300  of  FIG. 3  and the single-compartment cartridge body  902  of  FIG. 9 . Moreover, for one embodiment, essentially the same molding process used for cartridge body  102  ( FIG. 1 ) or cartridge body  300  ( FIG. 3 ), but with a different mold core for forming the interior, may form cartridge body  902 . 
     FIG. 10  is a three-dimensional representation of ink-jet cartridge  900  viewed from the bottom, according to another embodiment. Note that the head assembly  104  includes an orifice plate  1010  having a plurality of orifices  1015 . Orifices  1015  are communicatively coupled to compartment  910  for receiving ink therefrom through slots in the print head die that includes orifice plate  1010 . 
     FIG. 11  is a top view of cartridge body  902 , according to another embodiment. Outlet ports  1120   1 - 1120   4  are formed at the bottom of compartment  910 . For one embodiment, a capillary medium, bellows or other backpressure generating means may be disposed in compartment  910 .  FIG. 12  is a bottom view of cartridge body  902 , according to another embodiment. Cartridge body  902  includes a pair of ink-feed slots (or channels)  1220  that are communicatively coupled to outlet ports  1120 . In other words, outlet ports  1120  open into ink-feed channels  1220 . Ink-feed channels  1220  open directly to an exterior of cartridge body  902  and communicatively couple compartments  410  to the exterior of cartridge body  902 . Ink-feed channels  1220  are configured to respectively align with slots in the print head die on which orifice plate  1110  is mounted for delivering ink thereto. For one embodiment, portions of the bottom of cartridge body  902  surrounding ink-feed channels  1220  are attached directly to portions of the print head die that surround the slots of the print head die, e.g., using an adhesive or encapsulant. In operation, ink flows from compartment  910  ( FIGS. 9 and 11 ), through outlet ports  1120  ( FIGS. 11 and 12 ), into ink-feed channels  1220  ( FIG. 12 ), into the slots of the print head die and subsequently through orifices  1015  ( FIG. 10 ). It should be noted that although generally square or rectangular outlet ports  1120  are shown, they could be other shapes such as circles, slots, etc. Additionally, ink feed channels  1220  could be other shapes, sizes or eliminated altogether, as discussed above in conjunction with  FIG. 5 . 
   Note that a web  1130  is formed between the pair of outlet ports  1120   1  and  1120   2  and the pair of outlet ports  1120   3  and  1120   4  and extends in a direction from the pair of outlet ports  1120   1  and  1120   2  to the pair of outlet ports  1120   3  and  1120   4  in a direction perpendicular to the scanning direction  250 , as shown in  FIGS. 11 and 12 . 
     FIG. 13  is a cross-sectional view taken along line  13 - 13  of  FIG. 12 , according to another embodiment. In one embodiment a duct (or standpipe)  1320  is located within compartment  910  is connected (or opens) to outlet ports  1120   1 - 1120   4  (see  FIG. 11 ). Outlet ports  1120   2  and  1120   3  are shown opening into ink-feed channel  1220   2  in  FIG. 13 . Note that outlet ports  1120  may be located away from and between ends  1244  of feed channels  1220  for one embodiment. For another embodiment, a filter may be located over an inlet  1325  of duct  1320 . For one embodiment, the capillary material overlies the filter. The ratio of the length L C  of the cartridge body perpendicular to the scanning direction, perpendicular to the plane of  FIG. 13 , to a length L S  of ink-feed channel  1220   2  and/or a length of slots of a print head die perpendicular to the scanning direction is less than about 2. 
   Arrows  1350  ( FIG. 13 ) illustrate a flow path of ink from compartment  910  through duct  1320 , through outlet ports  1120   2  and  1120   3 , and into ink-feed channel  1220   2 . The ink-flow exits outlet ports  1120   2  and  1120   3  substantially vertically downward on either side of web  1130  and fills ink-feed channel  1220   2 . Note that a portion of the ink-flow expands to fill ink-feed channel  1220   2  as it exits outlet ports  1120   2  and  1120   3 . Note that the cartridge body  902  and ink-feed channels  1220  thereof are formed as single-piece and form a unitary structure. Attaching a print head nozzle array, such the print head die that includes orifice plate  1010  ( FIG. 10 ), seals ink-feed channels  1220  to the corresponding slots in the print head die. 
     FIG. 14  is a top view of a two-color, two-compartment ink-jet cartridge  1402 , according to another embodiment. Common reference numbers denote similar elements in  FIGS. 9 and 14 . For one embodiment, dividing the compartment  910  ( FIG. 11 ), by forming a partition  1420  on web  1130 , forms two compartments  1410  within ink-jet cartridge  1402  that are generally equal in volume. For another embodiment, outlet ports  1120   2  and  1120   4  and the web  1130  formed therebetween may be positioned such that the volume of compartments  1410  are respectively different fractions, e.g., about ⅓ and ⅔ (or the volume of one compartments  1410  is about ½ the volume of the other), of the volume of compartment  910 . As such, cover  106  ( FIG. 1 ) may be used to close compartments  1410 . Moreover, for one embodiment, essentially the same molding process used for cartridge body  902  ( FIG. 9 ), but with a different mold core for forming the interior, may form ink-jet cartridge  1402 . For one embodiment, a capillary medium, bellows or other backpressure generating means may be disposed in each of compartment  1410 . For other embodiments, compartments  1410  have substantially equal volumes. 
   Ink-jet cartridge  1402  includes a pair of ink-feed channels (not shown) that for one embodiment may be similar to ink-feed channels  1220  of  FIG. 12  or ink-feed channels  520  of  FIG. 5 . The ink-feed channels are communicatively coupled to outlet ports  1120 , as described above. The ink-feed channels open directly to an exterior of ink-jet cartridge  1402  and communicatively couple compartments  1410  to the exterior of ink-jet cartridge  1402 . The ink-feed channels are configured to respectively align with slots in a print head die on which an orifice plate is mounted for delivering ink thereto. For one embodiment, portions of the bottom of ink-jet cartridge  1402  surrounding the ink-feed channels are attached directly to portions of the print head die, e.g., using an adhesive or encapsulant. In operation, ink flows from compartment  1410 , through outlet ports  1120 , into the ink-feed channels, into the slots of the print head die, and subsequently through orifices of the orifice plate. For one embodiment, the ink-flow is substantially similar to the ink-flow depicted by arrows  1350  in  FIG. 13  or the ink-flow depicted by arrows  650  and  750  in  FIGS. 6 and 7 . In one embodiment, a duct (or standpipe)  1430  is located within each compartment  1410  and is connected (or opens) to an outlet port  1120 . 
   It should be noted that the various embodiments of a cartridge disclosed herein do not require plugs for plugging mold-slide-insert access holes and thus act to reduce manufacturing costs. 
   CONCLUSION 
   Although specific embodiments have been illustrated and described herein it is manifestly intended that the scope of the claimed subject matter be limited only by the following claims and equivalents thereof.