Patent Publication Number: US-8967777-B2

Title: Liquid ink containers for printing systems

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application is a Divisional of U.S. application Ser. No. 12/424,279, entitled Liquid Ink Container and Delivery Station, filed 15 Apr. 2009, which is incorporated herein in its entirety by this reference thereto. 
     This application is also related to PCT Application No. PCT/US10/31267, entitled Liquid Ink Container and Delivery Station, filed 15 Apr. 2010, which claims the benefit of U.S. application Ser. No. 12/424,279, entitled Liquid Ink Container and Delivery Station, filed 15 Apr. 2009. 
     The applicants hereby rescind any disclaimer of claim scope in the parent application or the prosecution history thereof and advises the USPTO that the claims in this application may be broader than any claim in the parent application. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Technical Field 
     The invention relates to the field of inkjet printing. More specifically, the invention relates to liquid ink delivery for large throughput printing applications. 
     2. Description of the Related Art 
     Inkjet printing involves depositing droplets of liquid ink onto a printing medium from one or more printer heads. The printer heads are coupled with a container containing ink. Ink is ejected from one or more nozzles of the print heads when a piezoelectric crystal in the print head is actuated. The piezoelectric crystal generates a pulse in the ink so that the ink expels through the nozzle as a droplet. To create the image, a carriage which holds one or more print heads scans or traverses across the printing medium, while the print heads deposit ink as the printing medium moves. 
     Small desktop inkjet printers are common consumer electronic products. Indeed, many consumer and business printing needs may be met by small desktop inkjet printing systems because of the relatively small amount of ink needed for common print jobs. However, some printing applications require much larger amounts of ink. For instance, large format printing is performed to create signs, banners, museum displays, sails, bus boards and the like. These types of applications require large throughput printers and require a much larger quantity of ink. 
     Ink cartridges are typically sold with replaceable ink reservoirs. Ink reservoirs are typically individually packaged and sold over the counter. However, common inkjet reservoirs contain far less ink than is required for large format printing. Currently, replacement reservoirs are not available in volumes greater than approximately five liters. Furthermore, the overhead cost associated with individually manufacturing, packaging and shipping small, individual replacement reservoirs is burdensome given that they must be replaced frequently to achieve large format printing. 
     Additionally, the ink used for inkjet printing is very expensive. This encourages designing printing systems that waste little ink. Some common containers for large format printing are designed to collapse in order to force the ink out of the cartridges and waste as little ink as possible. However, collapsible containers must be packaged in a protective shell or secondary container to protect the integrity of the container during shipping and handling. The secondary container adds to the overall cost of replacement ink. 
     SUMMARY OF THE INVENTION 
     In view of the foregoing, the invention provides a large liquid ink container and an ink delivery system for using the same. 
     In some embodiments of the invention, the liquid ink container is a large, substantially rigid receptacle designed for large format printing applications, wherein the receptacle does not need a secondary container to protect it during shipping. In some embodiments of the invention, the liquid ink container is substantially opaque. 
     In some embodiments of the invention, an ink delivery system is used to accept the large liquid ink container and designed to support the container at an angle, such that liquid ink flows from the container due to the force of gravity. In some embodiments, the ink delivery system includes protrusions disposed on the support surface. The protrusions are especially designed to mate with notches on the liquid ink container, such that the container self-aligns with the delivery system. 
     In some embodiments, an identification tag is disposed on the liquid ink container to provide information to a user regarding the contents therein. According to these some embodiments, the ink delivery system includes an identification tag reader, a processor, computer implemented instructions stored in a memory, and a user interface. Using these components, a user can view the content data. 
     In some embodiments, the ink delivery system includes a receiver configured to mate with the cap of the liquid ink container. According to these embodiments, a metal ring disposed within the receiver actuates, stamping a hole in the cap, thus initiating fluid ink flow. The self aligning features described above work synergistically with the cap puncturing means. 
     In some embodiments of the invention, the receiver includes a gas port and the cap includes a gas fitting. The gas port and gas fitting are aligned in fluid communication with one another when the receiver and the cap are coupled. The receiver also includes a nozzle for the introduction of forced gas. According to these embodiments, forced air traverses the receiver and the cap and is introduced into the liquid ink container. The forced gas helps facilitate evacuation of the liquid ink from the container. 
     In some embodiments of the invention, the ink delivery system includes a processor and computer implemented instructions stored on a memory device that automates fluid flow upon coupling the liquid ink container with the ink delivery system. The gas port, the gas fitting, the actuating metal ring, the processor and the self-aligning features offer a user-friendly ink delivery method. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1A  is an isometric view of a liquid ink container, according to some embodiments of the invention; 
         FIG. 1B  is an isometric view of the liquid ink container showing the bottom surface, according to some embodiments of the invention; 
         FIG. 2A  is an isometric view of an ink delivery station, according to some embodiments of the invention; 
         FIG. 2B  is an isometric view of a support surface which couples with the shelf of an ink delivery station, according to some embodiments of the invention; 
         FIG. 2C  is an isometric view of a liquid ink container coupled with an ink delivery station, according to some embodiments of the invention; 
         FIG. 2D  illustrates a schematic of the processing unit and user interface, according to some embodiments of the invention; 
         FIG. 2E  illustrates a schematic of a user interface with an ink level display having a bank of indicators according to some embodiments of the invention; 
         FIG. 3A  is an isometric view of a receiver according to some embodiments of the invention; 
         FIG. 3B  is another isometric view of the receiver, according to some embodiments of the invention; 
         FIG. 4A-1  and  FIG. 4A-2  are isometric views of a puncture cap and a receiver, according to some embodiments of the invention; 
         FIG. 4B-1  and  FIG. 4B-2  are other perspective views of the puncture cap and the receiver, according to some embodiments of the invention; 
         FIG. 5A  and  FIG. 5B  are isometric views of a liquid ink container and a support surface, according to some embodiments of the invention; and 
         FIG. 6  illustrates the process steps of a method of using a large, substantially rigid liquid ink container in a large throughput printing system, according to some embodiments of the invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Liquid Ink Container 
       FIG. 1A  is an isometric view of a liquid ink container  100 , according to some embodiments of the invention. The liquid ink container  100  is substantially hermetic and isolates liquid ink from atmospheric conditions such that the ink remains useable in liquid printing applications. In some embodiments of the invention, the liquid ink container  100  holds ultraviolet curable ink. According to these embodiments, the liquid ink container  100  is preferably opaque to the ultraviolet spectrum. 
     The liquid ink container  100  is configured with side notches  125 ,  126  and a cap  150 . The side notches  125 ,  126  define angled surfaces  127 ,  128 . In some embodiments, the liquid ink container is emptied into an ink delivery system (shown below) having a support surface and one or more support protrusions. The angled surfaces  127 ,  128  support the liquid ink container  100  at a downward angle when interfaced with appropriate extrusions on a support surface of an ink delivery station (explained below). When so positioned, the liquid ink container  100  empties due to the force of gravity on the ink contained therein. In some embodiments of the invention, the delivery of ink is automated and accomplished without manual interaction beyond placing the liquid ink container  100  in an inverted position within the ink delivery system. 
     In some embodiments, the cap  150  is designed to be punctured for allowing liquid ink to flow while the liquid ink container  100  is in the downward angle position. According to these embodiments, the cap  150  can be positioned on the very edge of the liquid ink container  100  such that when the liquid ink container  100  is emptied, ink does not pool up within the liquid ink container  100 . 
     In some embodiments of the invention, the liquid ink container  100  is substantially rigid. In these embodiments an additional shipping container may not be needed to protect the contents. 
     As explained above, common ink containers found in prior art must be collapsible in order to fully evacuate the ink therein. However, using a substantially rigid material discourages a collapsing system. Therefore, according to some of these embodiments, the liquid ink container  100  is configured with a gas fitting (explained below) for introduction of pressurized gas into the liquid ink container  100  to assist in the evacuation of the liquid ink contained therein. In some embodiments, the gas fitting is disposed in the cap  150 . The rigidity of the liquid ink container  100  is made possible by the disclosed method and corresponding apparatus for effective evacuation of ink from the liquid ink container  100  using forced gas (explained below). 
     The liquid ink container  100  also includes stacking lugs  131 ,  132  comprising protrusions from the top surface of the liquid ink container  100  and corresponding stacking recesses (explained below) in the bottom surface of the liquid ink container  100 . Accordingly, liquid ink containers  100  can stack upon one another, thus facilitating efficient storage and shipping. 
     In some embodiments of the invention, a swing handle  140  is coupled to the top surface of the liquid ink container  100 .  FIG. 1B  is an isometric view of the liquid ink container  100  showing the bottom surface  160 . As explained above, stacking recesses  133 ,  134  are disposed on the bottom surface  160 . Also on the bottom surface  160  is an integral handle  170 . The swing handle  140  and the integral handle  170  facilitate easy handling of the liquid ink container  100 . 
     In some embodiments of the invention the liquid ink container  100  is especially designed for large ink volume applications, such as fast throughput printing applications. In some embodiments, the liquid ink container  100  holds approximately twenty liters of liquid ink. According to some embodiments, the liquid ink container has the approximate dimensions of sixteen and one sixth inches by nine and three quarters inches by eleven and one quarter inches. 
     Identification of Liquid Ink Containers 
     In some embodiments of the present invention, the liquid ink container  100  includes an identification tag  180 . The identification tag  180  contains information relating to the contents of the liquid ink container  100 . For example, in some embodiments, the identification tag  180  includes information relating to the color of ink, the date the ink was manufactured, the name of the manufacturer of the ink, the quantity of ink, the expiration date of the ink, or combinations of these data. 
     In some embodiments of the invention, the identification tag  180  comprises a radio frequency identification (RFID) tag. According to these embodiments, the RFID tag contains encrypted data relating to the ink contained within the liquid ink container  100 . Operation of a RFID tag is described in greater detail in the commonly-assigned U.S. Pat. No. 7,431,436, which issued on Oct. 7, 2008, the entire contents of which are incorporated herein by reference. 
     Liquid Ink Container and Ink Delivery Station 
     In some embodiments of the invention, a liquid ink container and an ink delivery station are used together to produce synergistic results.  FIG. 2A  is an isometric view of an ink delivery station  299  according to some embodiments of the invention. The ink delivery station  299  includes a shelf  298  disposed at an acute angle from the horizontal plane, with a support surface  280  for supporting a liquid ink container. The shelf  298  is configured with support protrusions  297  upon which the side notches, e.g.  125 ,  126 , and the angled surfaces, e.g.  127 ,  128 , of a liquid ink container, e.g.  100 , interact to support the liquid ink container (as explained above). 
     In some embodiments, the notches, e.g.  125 ,  126 , and the support surfaces of the liquid ink container, e.g.  100 , securely accommodate the support protrusions  297 , thereby self-aligning the liquid ink container  100 , within the ink delivery station  299 . In some embodiments, the notches, the support surfaces of the liquid ink container  100  and the support protrusions  297  secure the liquid ink container  100  at an approximately twenty degree angle from the horizon while positioned in a level ink delivery station  299 . 
       FIG. 2B  is an isometric view of a support surface  280  which couples with the shelf  298  of an ink delivery station  299 . As explained above, the support surface  280  supports a liquid ink container, e.g.  100  ( FIG. 1A ,  FIG. 1B ),  200  ( FIG. 2C ),  500  ( FIG. 5A ). The support surface  280  includes support protrusions  297  and a conduit  296  into which the cap of a liquid ink container, e.g.  100 ,  200 ,  500 , partially extends. 
       FIG. 2C  is an isometric view of a liquid ink container  200  coupled with an ink delivery station  299  according to some embodiments of the invention. The ink delivery station  299  includes a shelf  298  and a support surface  280  as explained above. The ink delivery station  299  also includes a receiver  250  and ink delivery lines  240 . 
     The receiver  250  allows liquid ink to flow therethrough. In some embodiments of the invention, the receiver  250  punctures the cap  150  of the liquid ink container  200 , allowing the flow of liquid ink. In some embodiments of the invention, the receiver  250  contains a ring ( FIG. 3B ) for puncturing the cap  150  of the liquid ink container  200 . 
     In some embodiments, the receiver  250  is configured with a nozzle  260  for the introduction of pressurized gas. In some embodiments of the invention, the cap of the liquid ink container  200  is configured with a gas port (shown below) to facilitate the introduction of pressurized gas from the receiver into the liquid ink container  200 , for assisting the evacuation of the ink contained therein. 
     The liquid ink delivery system  299  also includes ink delivery lines  240  that couple with a printing station (not shown). In some embodiments of the invention, the liquid ink delivery system  299  couples with a dedicated printing station. In other embodiments, the liquid ink delivery station  299  is modular and compatible with wide variety of printing stations. 
     In some embodiments of the invention, the ink delivery station  299  also includes a processing unit  270  and a user interface  279 .  FIG. 2D  illustrates a schematic of the processing unit  270  and user interface  275 , according to some embodiments of the invention. The processing unit  270  comprises a processor  271 , a memory  272  containing machine readable instructions, a user input  273 , a RFID reader  277 , and outputs  274 ,  275 , and  276 . In some embodiments of the invention, the user input  273  comprises a button for initiating the automated ink delivery process disclosed below. 
     In some embodiments, output  274  comprises a metal ring actuator and output  275  comprises a nozzle actuator. In some other embodiments, the outputs  274 ,  275  and/or  276  comprise a pump for the introduction of forced air or an ink pump to deliver ink to the print station. According to these embodiments, the processing unit  270  can initiate the flow of liquid ink from the liquid ink container. In some embodiments, output  276  is the user interface  279 . 
     In some embodiments, the RFID reader  277  is positioned within the processing unit  270  of the ink delivery system  299 , such that it can read an RFID tag on the liquid ink container  200 . According to these embodiments, the processor  271  interprets information obtained from the RFID reader  277 , and displays it on the user interface  279 . 
     In some embodiments, additional inputs are used for displaying additional information on the user interface  279 .  FIG. 2E  illustrates a schematic of a user interface  279  with an ink level display  278  having a bank of indicators  999  according to some embodiments of the invention. In some embodiments, the bank of indicators  999  comprises a plurality of light-emitting diodes (LED). 
     The ink level display  278  communicates with, and is responsive to a float mechanism contained within the liquid ink container  200 . In some embodiments, the float mechanism has a discrete number of incremental sensors for determining the ink level at various different points in the vertical dimension inside the liquid ink container  200 . The float mechanism sends a signal through the processor  271 , and to the ink level display  278  on the user interface  279 , which lights up one or more indicators from the bank of indicators  999 . In some embodiments, one or more of the indicators within the bank of indicators  999  are colored differently from one or more other indicators. 
     Puncture Cap, Receiver, and Puncturing Ring 
       FIG. 3A  is an isometric view of a receiver  350 , according to some embodiments of the invention. The receiver  350  comprises a substantially cylindrical body  300 , a nozzle  330  for introduction of forced gas, a first terminal end  310  for coupling with a puncture cap, and a second terminal end  320  for coupling with ink delivery lines. The body  300  is substantially hollow to facilitate fluid flow through the receiver  350 . Included in the first terminal end  310  is a pressurized gas port  311  for delivering pressurized gas from the receiver  350  through the puncture cap to the liquid ink container. 
       FIG. 3B  is another isometric view of the receiver  350 , according to some embodiments of the invention.  FIG. 3B  details the first terminal end  310  of the receiver  350  and the pressurized gas port  311 . Within the cylindrical body  300  is a metal ring  340 . The metal ring  340  is actuated such that the metal ring  340  extends through the first terminal end  310  of the receiver  350 , for stamping a hole through the puncture cap, thus allowing liquid ink flow from the liquid ink container through the receiver  350 . 
     In some embodiments of the invention, the metal ring  340  is actuated by an electric actuator (not shown) coupled to the receiver  350 . Although electric actuation is explicitly disclosed, it will be readily apparent to those with ordinary skill in the relevant art having the benefit of this disclosure that a wide variety of other actuation devices (e.g. pneumatic actuation) are similarly applicable for actuating the metal ring  340 . 
     Forced Gas Evacuation 
     As explained above, it is common to use small, collapsible ink containers in printing applications. To ensure that little ink is wasted, the small ink containers are collapsed to consolidate ink in the gradually smaller volume of the container. This method is generally acceptable in small liquid ink container applications. 
     However, in high throughput printing applications, it is desirable to use large volume, substantially rigid liquid ink containers. Large volume containers provide more ink, thereby reducing the frequency of changing containers. Rigidity is desirable because it enables the containers to be shipped without additional packaging. However, substantially rigid liquid ink containers are not easily collapsible. Therefore, it would be desirable to ensure substantial evacuation of liquid from large, substantially rigid liquid ink containers, thereby limiting wasted ink. According to some embodiments of the invention, the liquid ink container is set at an angle, to facilitate gravity induced fluid flow. Additionally, gas is forced into the container, to further force the liquid ink out of the container, by the additional force of the gas on the remaining ink. 
     Cap Puncture and Introduction of Forced Gas 
       FIG. 4A-1  and  FIG. 4A-1  are isometric views of a puncture cap  451  and a receiver  450 . The puncture cap  451  couples with the liquid ink container, e.g.  100 , as shown in  FIG. 1A . When the liquid ink container  100  is coupled with the liquid ink delivery station  299 , the puncture cap  451  couples with receiver  450 . When coupled, forced gas from the receiver  450  traverses through the puncture cap  451  and into the liquid ink container  100  (not shown). 
     Forced gas is introduced to the receiver  450  through a nozzle  430 . The forced air traverses the body  400  via an internal conduit (not shown), and exits the receiver  450  via the pressurized gas port  411 . When coupled, the pressurized gas port  411  aligns with a gas fitting  460  coupled to the puncture cap  451 . In some embodiments, the gas fitting  460  contains a check valve (not shown) to allow gas to flow into the liquid ink container, e.g.  100 , but to prevent gas from flowing out of the liquid ink container  100  through the gas fitting  460 . 
     The puncture cap  451  is configured with a substantially hermetic conduit  475 . The conduit  475  is open on the inner side of the puncture cap  451  and sealed on the outer side of the puncture cap  451 . As explained above, the receiver  450  contains a metal ring  440  that is actuated. When the puncture cap  451  and the receiver  450  are coupled, the metal ring  440  aligns with the conduit  475 . When the metal ring  440  is actuated, it extends through the first terminal end  410 , into the conduit  475  of the puncture cap  451 , and stamps a hole in the sealed end of the conduit  475 . After actuation, liquid ink can freely flow from the liquid ink container, e.g.  100 , through the puncture cap  451 , through the receiver  450  and into delivery lines  240  (not shown). 
       FIG. 4B-1  and  FIG. 4B-2  are other perspective views of the puncture cap  451  and the receiver  450 . The puncture cap  451  is shown with the previously sealed end of the conduit stamped out by the metal ring  440 . Furthermore, the gas fitting  460  is in fluid communication with the conduit  475 . 
     As such, when the puncture cap  451  and the receiver  450  are coupled, forced gas from the nozzle  430  traverses the receiver  450  via an internal conduit (not shown), passes through the pressurized gas port  411 , enters the gas fitting  460  and flows into the conduit  475 . When the puncture cap  451  is coupled with a liquid ink container, e.g.  100 , forced gas enters the liquid ink container  100  via the conduit  475 , and helps evacuate liquid ink from the liquid ink container  100 . 
     Mating Features and Self-Alignment 
     In some embodiments of the invention, a liquid ink delivery station  299  and a liquid ink container, e.g.  100 , are designed with mating features for self-alignment. In the forced air evacuation systems, such as those described in  FIGS. 4A-1 ,  4 A- 2 ,  4 B- 1 , and  4 B- 2  above, the receiver  450  and the puncture cap  451  should be carefully aligned to facilitate proper puncturing, and proper alignment of the pressurized gas port  411  and the gas fitting  460 . These systems will benefit further by using mating features for self-alignment. 
     Referring again to  FIG. 2A , the ink delivery station  299  includes a shelf  298  with a support surface  280  for holding a liquid ink container, e.g.  100 ,  200  (not shown). The shelf  298  and the support surface  280  are disposed at an angle to facilitate fluid flow due to the force of gravity. The shelf  280  includes support extrusions  297 . 
       FIG. 5A  and  FIG. 5B  are isometric views of a liquid ink container  500  and a support surface  580  which couples with the shelf  298  of an ink delivery station  299 . As explained above, the support surface  580  supports the liquid ink container  500 . The liquid ink container  500  includes side notches  525 ,  526  and a puncture cap  550 . Likewise, the support surface  580  includes support protrusions  597  and a conduit  596 . The side notches  525 ,  526  and the support protrusions  597  mate upon placing the liquid ink container  500  in the support surface  580 . 
     Likewise, the puncture cap  550  mates with, and partially extends into, the conduit  596 . According to these embodiments, only a liquid ink container  500  with appropriate sized side notches  525 ,  526  will couple with the support surface  580 . Additionally, according to these embodiments, a force exerted to the puncture cap  550  will prevent the liquid ink container  500  from becoming decoupled from the support surface  580 . 
     As explained above, liquid ink containers using forced gas evacuation systems will benefit from the mating and self-alignment features. Particularly, self-alignment offers ease of user operation. The user simply places the liquid ink container  500  into the support surface  580  in order to ensure proper alignment of the puncture cap  550 . Accordingly, the user need not worry about further aligning the actuating metal ring  340 ,  440  of the receiver, e.g.  250 ,  350 ,  450  and the puncture cap  550 , or aligning the pressurized gas port, e.g.  311  ( FIG. 3A ,  FIG. 3B ),  411  ( FIG. 4A-2 ,  FIG. 4B-2 ) and the gas fitting  460  ( FIG. 4A-1 ). 
     Methods for Liquid Ink Delivery 
       FIG. 6  illustrates a method  600  for delivering liquid ink for large throughout printing applications, using a liquid ink delivery station  299  and large liquid ink containers, e.g.  100 ,  200 ,  500 . The method  600  begins with coupling a liquid ink container  100 ,  200 ,  500  with the liquid ink delivery station  299  at step  610 . In some embodiments, the liquid ink container  100 ,  200 ,  500  and the liquid ink delivery station  299  include mating features, self-alignment features, or both. The method continues with puncturing the puncture cap, e.g.  451 ,  550 , of the liquid ink container  100 ,  200 ,  500  to start fluid ink flow at step  620 . Next, after fluid flow begins upon puncturing the puncture cap  451 ,  550 , pressurized gas is introduced to the liquid ink  100 ,  200 ,  500  container at step  630 . The pressurized gas assists to evacuate the liquid ink container  100 ,  200 ,  500  and to deliver the ink to the printing system. 
     In some embodiments of the invention, the delivery station  299  includes a computer processor, e.g.  271  ( FIG. 2D ), for automating one or more steps in effectuating liquid ink delivery. In some embodiments, the processor  271  is electromechanically coupled with the actuator  274  within the receiver, e.g.  250 ,  350 ,  450 , and with the means for introducing pressurized gas into the receiver  250 ,  350 ,  450 . According to these embodiments, a user interface  279  is provided on the liquid ink delivery station  299 . 
     In some embodiments, the liquid ink container, e.g.  100 ,  200 ,  500 , and liquid ink delivery station  299  include mating features, and the method for delivering liquid ink  600  is automated. According to these embodiments, a user effects step  610  by manually placing a liquid ink container  100 ,  200 ,  500  into the liquid ink delivery station  299 . Next, the user interfaces with the delivery station  299  via a user interface  279 . The remainder of the method  600  is automated by the processor  271 , the electromechanically coupled actuator  274 , and means for introducing pressurized gas into the receiver  250 ,  350 ,  450 . 
     As will be understood by those familiar with the art, the invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Likewise, the particular naming and division of the members, features, attributes, and other aspects are not mandatory or significant, and the mechanisms that implement the invention or its features may have different names, divisions and/or formats. Accordingly, the disclosure of the invention is intended to be illustrative, but not limiting, of the scope of the invention, which is set forth in the following Claims.