Patent Publication Number: US-2006017789-A1

Title: Inkjet printer cartridge refilling machine and method of operation thereof

Description:
The present invention relates to an inkjet printer cartridge re-filling machine and method of operation thereof.  
     BACKGROUND OF THE INVENTION  
      It has previously been proposed to provide a machine for refilling substantially empty inkjet printer cartridges to enable the cartridges to be reused. Such cartridges typically have specific dimensions and external features specific to the manufacturer and the specific type of printer with which the cartridge is to be used. Importantly each cartridge will only operate successfully when filled with ink specific to the type of cartridge concerned. For example one cartridge of one manufacturer may require ink having different properties to ink required for a cartridge of another manufacturer. In addition one cartridge from one manufacturer may require a different type and volume of ink to another cartridge from the same manufacturer. The position of the chamber of each colour of ink may vary from one type of cartridge to another. In a retail situation it is desirable to be able to refill a plurality of different cartridges from different manufacturers relatively quickly. In many cases, it is desirable to be able to refill the customer&#39;s own cartridge while he/she waits. Once the customer&#39;s cartridge has been refilled a predetermined number of times, a new cartridge has to be purchased.  
      Prior ink cartridges include so called print head cartridges wherein the print head, controlling electronics and the ink chamber are all part of one removable unit. Often such ink cartridges have a similar shape but have dissimilar ink formulation, firing sequences or electrical circuitry.  
      Ink type can vary between different types of ink cartridge, some may, for example, use pigmented ink, others dye based ink, others photo quality ink. Often the different ink types are incompatible.  
      The above problems are particularly prevalent in the retail environment because of the relatively large number of different types of ink/toner cartridges that may need refilling.  
      Previous machines have comprised a plurality of ink nozzles each of which is connected to a respective, relatively large, supply of ink specific to a particular cartridge. The machine stores a number of these relatively large supplies of ink to account for the large variety of inkjet cartridges available. When a cartridge is required to be refilled by a particular nozzle of a type matching the cartridge concerned, the pipe work connecting the nozzle to the ink supply is first flushed out to avoid cross contamination with ink not compatible with the cartridge being refilled. The pipe work from that nozzle is then connected to a supply of ink suitable to refill the cartridge concerned. Ink is then pumped from the specific ink supply until the cartridge is refilled, after which the cartridge is removed. This process is relatively lengthy because of the flushing and reconnection steps. If another, different cartridge is to be refilled using the same nozzle (there being a space and cost based limit on how many nozzles can be provided), the pipes have again to be flushed and reconnected. Such machines, because of the large number of ink supplies required, are typically relatively large, unwieldy and time-consuming to operate.  
      To overcome this requirement of flushing and reconnection to different ink supplies, machines have been proposed which use what is commonly known as universal ink such that a plurality of different cartridge types are refilled with the same composition of ink. Whilst this process can be flexible and easy to operate, the use of such universal ink is generally considered to be unsatisfactory in terms of achieving consistent and reliable performance of the refilled ink cartridge.  
     SUMMARY OF THE INVENTION  
      According to a first aspect of the invention there is provided an inkjet printer cartridge refilling machine comprising first mounting means on which an empty printer cartridge can be mounted, nozzle means adapted to extend into the printer cartridge and deliver ink to the printer cartridge, a second mounting means adapted to releasably mount a cassette containing ink of the specific type and volume required to refill the empty printer cartridge, the arrangement being such that the cassette, when mounted on the machine, is connected to the nozzle means, the machine being operative to deliver ink from the cassette to the printer cartridge to refill the printer cartridge.  
      By printer cartridge we mean any ink or toner cartridge as used, for example, on printers, fax machines and photocopiers.  
      Preferably the first and second mounting means and the nozzle means form a module which is itself adapted to be removably mounted on the machine.  
      Preferably the machine comprises a plurality of modules.  
      Preferably the nozzle means of each module comprises a first set of nozzles adapted to be inserted into the cartridge to be refilled, and a second set of nozzles adapted to be inserted into the cassette, the two sets of nozzles being in communication with one another.  
      Preferably at least one of the modules of each machine is adapted to refill cartridges of a different type to that of another module. Preferably the first set of nozzles of different modules are specific to a particular type of cartridge and thus differ between modules, whilst the second set of nozzles of different modules are preferably substantially identical, the cassettes also being substantially identical.  
      Preferably at least one of the first set of nozzles and the first mounting means are movably mounted on the module to permit relative movement between the first set of nozzles and the first mounting means such that the first set of nozzles can enter the cartridge to be refilled.  
      Preferably at least one of the first set of nozzles and the first mounting means are mounted on a carriage slidably mounted on the module.  
      Preferably movement of the carriage is effected by a user operated handle on the carriage.  
      Preferably at least one of the second set of nozzles and the second mounting means are movably mounted on the module to permit relative movement between the second set of nozzles and the second mounting means such that the second set of nozzles can enter the cassette.  
      Preferably at least one of the second set of nozzles and the second mounting means are mounted on a carriage slidably mounted on the module.  
      Preferably movement of the carriage is effected by a user operated mechanism on the carriage. Most preferably the mechanism comprises part of the second mounting means that is operative when a cassette is mounted on the second mounting means by a user.  
      Preferably the machine comprises pump means operative, in use, to pump ink from the cartridge to be refilled, and to pump fresh ink from the cassette to the cartridge.  
      Preferably the pump means comprises at least one peristaltic pump.  
      Preferably each module comprises control means operative to automatically control the operation of the pump means upon receipt of a user generated control signal.  
      The control means preferably comprises a programmable memory, for example an EPROM.  
      The control means preferably further comprises a display indicative of the program selected by the user.  
      Preferably the display is a touch screen display.  
      According to a second aspect of the invention there is provided a method of refilling an inkjet printer cartridge comprising an ink cassette that contains a single charge of ink or inks of sufficient volume/s to refill the printer cartridge, bringing the printer cartridge relatively into co-operation with a nozzle means, removing ink from the cassette through nozzle means, and supplying the nozzle means, whilst the nozzle means is co-operating with the cartridge, with ink from the cassette so as to replenish the cartridge.  
      Preferably the step of removing ink comprises activating pump means to pump old ink from the printer cartridge and into ink disposal means.  
      Preferably the supplying step comprises moving the second set of nozzles and/or the cassette such that the second set of nozzles enters a region of predetermined weakness of the cassette to such an extent that the nozzle inlets are adjacent with the base of the cassette.  
      Preferably the nozzle inlets are adjacent to the recess at the base of the cassette.  
      Preferably means are provided operative to control the pump means such that only the amount of ink required to fill the printer cartridge is pumped from the cassette.  
      Preferably the method further comprises a cartridge priming step wherein ink from the refilled cartridge is drawn out of the print head of the cartridge to induce flow of the ink from the cartridge.  
      Preferably the method further comprises a final evacuation step wherein after the refilled cartridge has been removed, the pump means pumps ink residual in the nozzle means out of the nozzle means and back into the cassette.  
      According to a third aspect of the invention there is provided an ink cassette for use with the machine of the first aspect of the invention, the cassette comprising at least one chamber to receive and contain sufficient ink to refill an empty inkjet printer cartridge, and means to enable the cassette to be removably mounted on the machine.  
      Preferably the cassette comprises a plurality of ink chambers.  
      Preferably the or each chamber comprises a sealed chamber having a region of predetermined weakness positioned so as to be aligned with the second set of nozzles when the cassette is mounted on the machine so that the second set of nozzles, in use of the machine, extend through the region of predetermined weakness.  
      Preferably the region of predetermined weakness comprises an aperture sealed by a portion of sheet material. Preferably the material is a pierceable plastics sheet material. The sheet material may comprise a metallic foil or silicone compound or any other suitable pierceable and sealable material.  
      Preferably the or each chamber comprises a base provided with a recess that in use of the cassette comprises the lowermost part of the chamber of the cassette.  
      Preferably the region of predetermined weakness is positioned on the ceiling of the chamber so as to be opposed to the base and the recess such that when the cassette is mounted on the machine the recess is lowermost such that ink contained in the cassette flows under the influence of gravity into the recess.  
      Most preferably when the cassette is mounted on the machine, at least one nozzle of the second set of nozzles is aligned with the recess. Preferably each nozzle is aligned with a respective recess.  
      Other aspects of the present invention may include any combination of the features or limitations referred to herein. 
    
    
     DESCRIPTION OF THE DRAWINGS  
      The present invention may be carried into practice in various ways, but embodiments will now be described by way of example only with reference to the accompanying drawings in which:  
       FIG. 1  is a perspective view of a printer inkjet refilling machine in accordance with the present invention;  
       FIG. 2  is a side view of a module comprising part of the machine of  FIG. 1 ;  
       FIG. 3   a  is an enlarged perspective view of the module of  FIG. 2 ;  
       FIG. 3   b  is an enlarged front view of part of the module of  FIGS. 2 and 3   a.    
       FIG. 4  is a rear view of the module of  FIGS. 2 and 3 ;  
       FIG. 5  is a schematic side view of the rear of the module of FIGS.  2  to  4 ;  
       FIG. 6  is a perspective view of an ink cassette in accordance with the present invention; and  
       FIG. 7  is a side view of the cassette of  FIG. 6 . 
    
    
     DETAILED DESCRIPTION OF THE INVENTION  
      Referring initially to  FIG. 1 , a inkjet printer cartridge refilling machine  1  comprises an oblong storage cabinet  3  and a back plate  5  comprising a hollow, oblong, open-fronted box  6  on which is mounted a plurality of refilling modules  7 . Any number of modules  7  may be provided so as to extend, if necessary, from one side margin of the back plate  5  to the other. The cabinet  3  could be made from any suitable material including sheet metal.  
      The function and programming of each module  7  is controlled by separate printed circuit boards (PCBs—not shown) located at the back of each module  7 . The PBCs can control, inter alia, the amount of ink to be dispensed, emptying cycles and the operation and timing of pump means.  
      In addition each PCB is interconnected into a single line which exits the machine into a diagnostic plug (not shown). By connecting a separate computer to the diagnostic plug, a user may re-programme any or all of the modules  7  to change, for example, filling or emptying parameters.  
      In addition, if required in a retail environment, the diagnostic plug can be used to count the number of re-fills each module  7  completes at the end of a certain period, for stock take, revenue reconciliation or other accountancy and control purposes.  
      Referring additionally to FIGS.  2  to  5  each module  7  comprises a mounting plate  9  adapted to be removably secured to the open front of the box  6  using any suitable method which, for example, may comprise a quick release attachment mechanism as is well known.  
      A carriage  11  extends perpendicularly from the front side of the plate  9 . The carriage  11  is slidably mounted on the plate  9  so as to be able to move up and down the front of the plate  9 . A handle  13  is provided to facilitate this movement, the handle  13  being connected to the carriage  11  by a suitable linkage operative to raise the carriage  11  as the handle  13  is lowered and vice versa.  
      Three ink injector nozzles  12  extend from the carriage  11  through the base of the carriage  11 . A planar guide plate  16  is provided beneath the carriage  11  through which the nozzles  12  extend to help maintain the relative spacing of the nozzles  12 .  
      Three ink nozzle connectors  15  are mounted on the top of the carriage  11  and are each in fluid communication with a respective one of the injector nozzles  12 .  
      A printer cartridge receiving box  18  is located on the plate  9  below the carriage  11  and the nozzles  12  and comprises a recessed upper support surface  20 . A printer cartridge to be refilled is, in use, placed on support surface  20  of the box  18 . The box  18  and the support surface  20  are of a size and shape specific to correspond to the print head of the particular type of cartridge to be refilled and is such that when the cartridge is mounted in the box  18 , a preformed refilling aperture at the base of each ink chamber of the cartridge is aligned with a respective ink injector nozzle  12 .  
      The support surface  20  and the base of the box  18  are formed with a number of drainage apertures  22 , the number usually corresponding to the number of ink chambers provided in the cartridge. Each drainage aperture  22  in the base of the box  18  is connected to a respective drainage pipe  24  that is connected to pump means comprising a peristaltic pump  19  driven by a DC electric motor  21 . The pump  19  is in communication with an ink disposable receptacle (not shown) in which unwanted ink can be stored for disposal.  
      The cartridge is mounted on the box  18  with the print head lowermost so as to be in contact with support surface  20 , and the base of the cartridge uppermost so that the refilling apertures are adjacent respective ink injector nozzle  12 . When so mounted, the print head of the cartridge is adjacent the drainage apertures  22  in the support surface  20 .  
      When the handle  13  is raised, the injector nozzles  12  are lowered with the carriage  11  such that the injector nozzles  12  extend into the printer cartridge. This is the position shown in FIGS.  2  to  4  although the cartridge itself has been omitted for clarity. When the carriage  11  is in the uppermost position, the injector nozzles  12  do not extend into the cartridge and the cartridge can be removed and replaced with another cartridge.  
      A support frame  23  is mounted on the rear face of the plate  9  and an aperture  25  is formed in the plate  9  so as to be aligned with the frame  23 . A closure comprising a door  27  of any suitable type including, for example, a sliding of L-shaped cross-section is provided to close the frame  23 . The frame  23  is dimensioned to receive an ink cassette  29  which functions as a supply of fresh ink of the type and volume required by the specific printer cartridge to be refilled.  
      A second set of connecting nozzles  31  are provided on a carriage  32  slidably mounted on the rear face of the mounting plate  9 , each of the connecting nozzles  31  terminating in a respective ink receiving needle  37 . The carriage  32  is movable to a position in which the needles  37  extend into the cassette  29  via a needle guide  40 .  
      The nozzles  31  are connected, via suitable pipe work  38  to pump means comprising a peristaltic pump  33  driven by a DC electric motor  34 . The other side of the pump  33  is connected, to the connectors  15  on the carriage  11  that feed the printer cartridge. The carriage  32  is connected to the door  27  or the frame  23  by a suitable linkage operative such that as the door  27  is closed, the linkage moves the carriage  32  downwardly such that the ink receiving needles  370  enter the cassette  29 .  
      Referring additionally to  FIGS. 6 and 7 , the ink cassette  29  comprises, in this example, three adjacent, substantially oblong chambers  41  that are sealed by a planar lid  43 . The lid  43  comprises three circular apertures  47  that are positioned, when the lid  43  is mounted on the cassette  29  and the cassette  29  is received in the box  23 , to be aligned with a respective one of the needles  37  of the second set of nozzles  31 . Prior to use, the apertures  47  of the lid  43  are sealed closed using, for example, a strip or foil of adhesive backed material (not shown). The material can be any suitable material including, for example, a plastics material, a silicone compound, a metal foil material or an adhesive backed paper material. Thus the apertures  47  and the sealing strip together comprise a region of predetermined weakness adapted to be pierced by the needles  37 . The region of predetermined weakness could be provided by any other suitable means including, for example, serrations or partial cuts in the lid  43 .  
      The base of each chamber  41  of the cassette  29  is formed with a respective hemispherical recess  50  that comprises the lowermost part of that chamber  41  and is therefore the part of the cassette  29  to which any ink contained in the chamber  41  will flow under the influence of gravity when the cassette  29  is mounted on the machine  1 .  
      The base of one of the chambers  41  of the cassette  29  is formed with a male lug  51  that projects outwardly of the cassette  29 . This lug  51 , in use, is received in a corresponding female formation provided on the box  23  which ensures that the cassette  29  is inserted into the box  23  in the correct orientation. This is to ensure that the chambers  41  of the cassette  29  are, in use, in communication with the correct nozzles  31  to avoid any ink cross contamination as each ink chamber  41  may contain ink of a different colour, type or composition.  
      It will be appreciated that the cassette  29  could comprise any number of chambers  41 , including only one chamber  41 , so as to correspond to the number of ink chambers  41  provided in the cartridge to be refilled.  
      Control means  50  are provided to control the operation of the carriages  11 ,  32  and the pumps  19 ,  33 . The control means  50  can comprise any suitable means including, for example, an electronic data processor comprising a printed circuit board or boards. A display, which may be an LCD display, or an LED display, can be provided to indicate information concerning the operation or status of the machine  1 . The display may be a touch screen display operative to enable the user to start, stop or monitor the machine  1 .  
      In use, a user places the cartridge to be refilled in the box  18  on the front of the plate  9  with the print head of the cartridge resting on the support surface  20 . The handle  13  is initially in the lowermost position such that the carriage  11  and the injector nozzles  12  are spaced above the box  18  and the top of the cartridge. The refilling apertures  22  of the cartridge (not shown) are aligned with respective ink injector nozzles  12 . The user then inserts a cassette  29  onto the frame  23  and closes the door  27 , the lug  51  on the cassette  29  providing a physical barrier to this insertion if the user attempts to insert the cassette  29  in an incorrect orientation.  
      The number of chambers  41  of the cassette  29  correspond to the number of inks required to fill the cartridge. Each chamber  41  of the cassette  29  also contains ink of a type and volume specifically corresponding to the type of ink required by the specific type of ink cartridge to be refilled. Indicia may be provided on the cassette  29  indicative of the type of cartridge that can be refilled by that particular cassette  29 .  
      The user then raises the handle  13  which lowers the first carriage  11  downwardly such that the ink injector nozzles  12  enter respective chambers of the ink cartridge. Switch means may be provided to complete a circuit when the handle  13  is fully lowered so as to activate the emptying and refilling cycle and other pre-programmed cycles.  
      The first pump  19  is then activated by the control means  50  to draw ink remaining in the cartridge out of the cartridge, through the drain apertures  22  and pipe work  24 , into the pump  19  and into the ink disposal receptacle mounted elsewhere in the machine. Sensor means may be provided to determine when sufficient ink has been drawn out of the cartridge. This is to ensure that when the refilling operation is complete, substantially only fresh ink is contained in the cartridge.  
      The second carriage  32  has already been lowered towards the cassette  29  as the door  27  to the aperture  25  was closed. The carriage  32  is lowered to such an extent that respective ink receiving needles  37  pierce the foil sealing each cassette chamber  41  and enter the respective chambers  41 . The carriage  32  is lowered until the tip of the needles  37  are adjacent the lowermost point in each chamber  41 , namely the lowermost point of each recess  50 .  
      The second pump  37  is then activated by the control means  50  to draw fresh ink out of the cassette  29 , through the ink receiving needles  37 , through the connecting pipe work  38 , through the connectors  15 , through the nozzles  12  and into the cartridge  20 . Means are provided to determine when the cartridge is full or substantially full. This may be achieved by sensing the volume of ink pumped through the connecting pipe work  38  or through the valve arrangement and ensures that the volume of ink pumped into the cartridge does not exceed the cartridge ink capacity.  
      When the cartridge is sufficiently refilled the second pump  33  is deactivated.  
      The control means  50  then begins a priming cycle to induce ink flow from the cartridge print head. This helps ensure that ink will flow from the cartridge when the cartridge is used in a printer later on. This is achieved by reactivating the pump  19  so as to draw fresh ink from the cartridge, through the drainage apertures  22  of the cartridge, and through the pipe work  24  to induce ink flow from the refilled cartridge. Once primed the printer cartridge head is sealed to prevent further ink flow until the cartridge is used in a printer.  
      After the above priming steps, the pump  33  is reactivated to pump any ink residual in the ink injector nozzles  12 , the pipe work  38 , the connectors  15  and the connecting nozzles  31  back into the cartridge  29 .  
      This ensures that the ink receiving needles  37  and pipe work  38  are substantially free of ink before beginning the above process again with another empty cartridge. This removes static ink from the pipe work  38 .  
      A number of different modules  7  can be provided on the machine  1 . Each module may have first set of nozzles  12  specific to fit a particular type, size and shape of cartridge. The shape and dimensions of the cassette  29  may be the same for each module  7  or may be different depending upon the number of different types of ink required to refill the cartridge concerned, and the volume of ink required. The shape and size of the box  18  and the support surface  20  may be different for different modules  7  so as to correspond to the specific size and shape of the print head of the cartridge to be refilled using each specific module.  
      The machine  1  provides a substantially automated, easy to use and relatively quick method of refilling a wide variety of different models of empty or partially empty printer inkjet cartridges at a point of sale or retailer environment. Through the use of cassettes  29  it allows the machine operator to substantially and easily switch between various ink compositions without the requirement for additional and complex ink feeding systems or the necessity to flush out such systems prior to a specific or individual cartridge refilling process commencing.  
       FIG. 1  above shows one form of the machine comprising ten modules  7  in a cabinet  3  which is approximately two metres long and weighs approximately a quarter ton. This cabinet  3  is a sheet metal vehicle for the modules  7 .  
      Alternative arrangements for mounting the modules  7  are envisaged, for example, as follows:  
      A five module relatively small machine could be provided for photo cartridge use only. This may be mounted on a table or a check out counter, and could, for example, be in a carousel form in the shape of a pentagon, which can be rotated depending upon the modules  7  in use.  
      A twelve module machine could be provided wherein the modules  7  are arranged in a back to back formation. Such a machine would fit, for example, within a one metre squared floor space and could comprise a lower cabinet and two rows of six modules  7  sitting back to back on the lower cabinet. The operator can walk around the machine depending upon which modules  7  are in use.  
      A rotating carousel type machine for twelve modules  7  standing on its own base could be provided. This would be designed to stand in the centre floor of a busy shop, rather like a revolving postcard display.  
      A starter machine could be provided for, for example, six modules  7 , which could be built up on a modular basis two modules  7  at a time. This would be a smaller machine designed to have more modules  7  bolted on as the retailer&#39;s business grows.  
      A wall mounted machine could be provided. Up to twelve modules  7  could be wall mounted, perhaps in one long straight row, or mounted in a stacked formation of two rows of six modules  7 . In this way modules  7  could be put into premises where floor space is very limited.