Abstract:
A printhead is provided for an inkjet printer that has a print engine controller for receiving print data and sending it to the printhead. The printhead has a printhead IC for ejecting ink and a support structure for mounting the printhead IC in the printer adjacent a paper path. The printhead IC is mounted on a face of the support structure that, in use, faces the paper path. A flexible printed circuit board (flex PCB) that has contacts for receiving print data mounted to the support structure on a face that does not face the paper path. The bent section reduces the likelihood of trace cracking by holding the flex PCB at a set radius rather than allowing the flex to follow an irregular curve and thereby risking localized points of high stress on the traces.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 11/688,873 filed Mar. 21, 2007 all of which is herein incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention relates to printers and in particular inkjet printers. 
         [0003]    1. Co-Pending Applications 
         [0004]    The following applications have been filed by the Applicant with the present application: 
         [0000]    
       
         
               
               
               
               
               
             
           
               
                   
               
             
             
               
                 11/688,863 
                 11/688,864 
                 7,475,976 
                 7,364,265 
                 11/688,867 
               
               
                 11/688,868 
                 11/688,869 
                 11/688,871 
                 11/688,872 
               
               
                   
               
             
          
         
       
     
         [0005]    The disclosures of these co-pending applications are incorporated herein by reference. 
         [0006]    2. Cross references 
         [0007]    The following patents or patent applications filed by the applicant or assignee of the present invention are hereby incorporated by cross-reference. 
         [0000]    
       
         
               
               
               
               
               
             
           
               
                   
               
             
             
               
                 6,405,055 
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                 7,566,106 
                 7,350,913 
                 7,284,816 
               
               
                 7,469,989 
                 7,431,424 
                 7,470,006 
                 7,328,984 
                 7,347,534 
               
               
                 7,322,671 
                 7,467,863 
                 7,367,650 
                 7,469,990 
                 7,585,054 
               
               
                 7,556,364 
                 7,441,865 
                 7,467,852 
                 7,431,440 
                 7,431,443 
               
               
                 7,441,882 
                 7,524,023 
                 7,357,496 
                 11/495,819 
                 7,465,045 
               
               
                 7,645,034 
                 7,527,353 
                 7,645,033 
                 7,513,603 
                 7,111,935 
               
               
                 11/677,049 
                 11/677,050 
                 7,637,602 
                 7,306,320 
                 11/495,818 
               
               
                 7,002,664 
                 7,562,971 
                 10/760,219 
                 11/677,051 
                 7,261,482 
               
               
                 7,079,292 
                 7,540,601 
                 10/760,252 
                 7,088,420 
                 7,604,322 
               
               
                 7,470,014 
                 10/760,220 
                 7,201,272 
                 11/599,312 
                 7,377,635 
               
               
                 11/446,233 
                 7,237,888 
                 7,470,020 
                 7,210,407 
                 6,991,098 
               
               
                 7,217,051 
                 11/014,727 
                 10/760,215 
                 7,168,654 
                 10/760,260 
               
               
                 7,186,042 
                 10/760,266 
                 6,944,970 
                 7,217,049 
                 7,108,434 
               
               
                 7,611,237 
                 7,147,102 
                 7,287,828 
                 6,920,704 
                 10/760,241 
               
               
                 7,607,756 
                 7,191,978 
                 7,261,477 
                 7,225,739 
                 7,249,838 
               
               
                 10/962,425 
                 7,431,446 
                 7,258,415 
                 10/962,426 
                 7,524,046 
               
               
                 10/962,402 
                 10/962,403 
                 7,419,053 
                 7,270,401 
                 7,322,677 
               
               
                 7,258,424 
                 10/962,417 
                 7,195,412 
                 7,163,287 
                 11/706,298 
               
               
                 7,220,072 
                 7,588,381 
                 7,484,841 
                 11/585,925 
                 7,207,670 
               
               
                 7,322,761 
                 7,575,316 
                 7,384,206 
                 11/544,547 
                 11/223,018 
               
               
                 7,578,387 
                 11/223,021 
                 11/014,730 
                 11/223,020 
                 11/223,262 
               
               
                   
               
             
          
         
       
     
       BACKGROUND OF THE INVENTION 
       [0008]    The Applicant has developed a wide range of printers that employ pagewidth printheads instead of traditional reciprocating printhead designs. Pagewidth designs increase print speeds as the printhead does not traverse back and forth across the page to deposit a line of an image. The pagewidth printhead simply deposits the ink on the media as it moves past at high speeds. Such printheads have made it possible to perform full colour 1600 dpi printing at speeds in the vicinity of 60 pages per minute, speeds previously unattainable with conventional inkjet printers. 
         [0009]    Printheads are typically controlled by a micro-processor within the printer, often referred to as a print engine controller (PEC). If a printhead is provided in a removable cartridge form, the PEC and the printhead must communicate via a detachable electrical interface—usually complementary contact pads. The contacts on the printhead should be close to the nozzles in the printhead integrated circuit (IC) for optimal electrical efficiency and operation. However, there are compelling reasons to keep the paper path adjacent the printhead straight instead of curved or angled. This requires the contacts to be positioned on a different side of the cartridge (not the side holding the printhead IC). The contacts then connect to the printhead IC via a flexible printhead circuit board (or flex PCB as it is known). The flex PCB wraps around a corner of the cartridge to connect the contacts to the printhead IC. 
         [0010]    The conductive paths in the flex PCB are known as traces. As the flex PCB must bend around a corner, the traces can crack and break the connection. To combat this, the trace can be bifurcated prior to the bend and then reunited after the bend. If one branch of the bifurcated section cracks, the other branch maintains the connection. Unfortunately, splitting the trace into two and then joining it together again can give rise to electro-magnetic interference problems that create noise in the circuitry. 
         [0011]    Making the traces wider is not an effective solution as wider traces are not significantly more crack resistant. Once the crack has initiated in the trace, it will propagate across the entire width relatively quickly and easily. Careful control of the bend radius is more effective at minimizing trace cracking, as is minimizing the number of traces that cross the bend in the flex PCB. 
         [0012]    Pagewidth printheads present additional complications because of the large array of nozzles that must fire in a relatively short time. Firing many nozzles at once places a large current load on the system. This can generate high levels of inductance through the circuits which can cause voltage dips that are detrimental to operation. To avoid this, the flex PCB has a series of capacitors that discharge during a nozzle firing sequence to relieve the current load on the rest of the circuitry. Unfortunately, the capacitors and other components associated with the drive circuitry create additional traces that risk cracking in the bent section of the flex PCB. 
       SUMMARY OF THE INVENTION 
       [0013]    Accordingly, in a first aspect the present invention provides a printhead for an inkjet printer, the printhead comprising: 
         [0014]    a printhead integrated circuit (IC) with an array of nozzles for ejecting ink; 
         [0015]    a support structure for supporting the printhead IC, the support structure having ink conduits for supplying the array of nozzles with ink; and, 
         [0016]    a fluidic damper containing gas for compression by pressure pulses in the ink within the ink conduits to dissipate the pressure pulse. 
         [0017]    Damping pressure pulses using gas compression can be achieved with small volumes of gas. This preserves a compact design while avoiding any nozzle flooding from transient spikes in the ink pressure. 
         [0018]    Optionally, the fluidic damper has an array of cavities for holding the gas such that each cavity is a separate pocket of the gas. Optionally, each of the cavities is partially defined by an ink meniscus when the ink conduits of the support structure are primed with ink. 
         [0019]    Optionally, each of the cavities is a blind recess with an opening facing one or more of the ink conduits. Optionally, the opening of each of the blind recesses faces one of the ink conduits only. Optionally, the opening of each of the blind recesses of configured to inhibit ink filling the recess by capillary action. 
         [0020]    Optionally, the support structure has an inlet for connecting the ink conduits to an ink supply and an outlet for connecting the ink conduits to a waste ink outlet. Optionally, the openings to each respective cavity have an upstream edge and a downstream edge, the upstream edge contacting the ink before the downstream edge during initial priming of the ink conduits from the ink supply, and the upstream edge having a transition face between the conduit and the cavity interior, the transition face being configured to inhibit from filling the cavity and purging the gas by capillary action during initial priming of the ink conduit. 
         [0021]    Optionally, the printhead is a pagewidth printhead and the support structure is elongate with the inlet at one end and the outlet at the other end, and the ink conduits have channels extending longitudinally along the support structure between the inlet and the outlet, and each of the channels have a series ink feed passages spaced along it to provide fluid communication between the channel and the printhead IC. Optionally, the ink feed passages join to the channel along a wall of the channel that is opposite the wall including the openings to the cavities. 
         [0022]    Optionally, the support structure is a liquid crystal polymer (LCP). Optionally the support structure is a two-part LCP molding with the channels and the feed passages formed in one part and the cavities formed in the other part. 
         [0023]    Optionally, the support structure has a plurality of printhead ICs mounted end to end along one side face. Optionally the printhead ICs are mounted to the side face via an interposed adhesive film having holes for fluid communication between the ink feed passages and the printhead ICs. 
         [0024]    Accordingly, in a second the present invention provides a printhead for an inkjet printer, the printhead comprising: 
         [0025]    a printhead integrated circuit (IC) having an array of nozzles for ejecting ink; and, 
         [0026]    a support structure for mounting the printhead IC within the printer, the support structure having ink conduits for supplying the array of nozzles with ink, the ink conduits have a weir formation to partially obstruct ink flow; wherein, 
         [0027]    when priming the printhead, the weir formation preferentially primes an upstream section the ink conduit. 
         [0028]    Using a weir downstream of areas that have a propensity to prime incorrectly can force them to prime more quickly or in preference to downstream sections. As long as the downstream section is one that reliably primes, albeit delayed by the weir, there is no disadvantage to priming the upstream section in preference. 
         [0029]    Optionally, the weir formation has a top profile configured to provide an anchor point for the meniscus of an advancing ink flow. Optionally, the upstream section has cavities in its uppermost surface that are intended to hold pockets of air after the printhead has been primed. Optionally, the cavities have openings defined in the uppermost surface of the upstream section, the upstream edge of each opening being curved and the downstream edge being relatively sharp so that ink flowing from the upstream direction does get drawn into the cavity by capillary action. Optionally the weir is positioned to momentarily anchor the meniscus of the advancing ink flow and divert it from contact the relatively sharp edge of the opening for one of the cavities. Optionally, the printhead is a cartridge configured for user removal replacement. Optionally, the cartridge is unprimed when installed and subsequently primed by a pump in the printer. 
         [0030]    Accordingly, in a third aspect the present invention provides a printhead for an inkjet printer, the printhead comprising: 
         [0031]    an elongate array of nozzles for ejecting ink; 
         [0032]    a plurality of ink conduits for supplying the array of nozzles with ink, the ink conduits extending adjacent the elongate array; and, 
         [0033]    a plurality of pulse dampers, each containing a volume of gas for compression by pressure pulses in the ink conduits, and each being individually in fluid communication with the ink conduits; wherein, 
         [0034]    the pulse dampers are distributed along the length of the elongate array. 
         [0035]    A pressure pulse moving through an elongate printheads, such as a pagewidth printhead, can be damped at any point in the ink flow line. However, the pulse will cause nozzle flooding as it passes the nozzles in the printhead integrated circuit, regardless of whether it is subsequently dissipated at the damper. By incorporating a number of pulse dampers into the ink supply conduits immediately next to the nozzle array, any pressure spikes are damped at the site where they would otherwise cause detrimental flooding. 
         [0036]    Optionally, the plurality of pulse dampers are a series of cavities open at one side to the ink conduits. Optionally, each the cavities has an opening in only one of the ink conduits, each of the ink conduits connect to a corresponding ink supply and the openings are configured such that the cavities do not prime with ink when the ink conduits are primed from the corresponding ink supply. 
         [0037]    Optionally, each of the cavities is a blind recess such that the opening defines an area substantially equal to that of the blind end. Optionally, the openings each face one of the ink conduits only. Optionally, the openings are configured to inhibit ink filling the recess by capillary action. 
         [0038]    Optionally, the openings to each respective cavity have an upstream edge and a downstream edge, the upstream edge contacting the ink before the downstream edge during initial priming of the ink conduits from the ink supply, and the upstream edge having a transition face between the conduit and the cavity interior, the transition face being configured to inhibit from filling the cavity and purging the gas by capillary action during initial priming of the ink conduit. 
         [0039]    Optionally, the array of nozzles is formed in at least one printhead IC mounted to a support structure in which the ink conduits are formed. Optionally, the printhead is a pagewidth printhead and the support structure is elongate with the inlet at one end and the outlet at the other end, and the ink conduits have channels extending longitudinally along the support structure between the inlet and the outlet, and each of the channels have a series ink feed passages spaced along it to provide fluid communication between the channel and the printhead IC. Optionally, the ink feed passages join to the channel along a wall of the channel that is opposite the wall including the openings to the cavities. 
         [0040]    Optionally, the support structure is a liquid crystal polymer (LCP). Optionally the support structure is a two-part LCP molding with the channels and the feed passages formed in one part and the cavities formed in the other part. 
         [0041]    Optionally, the support structure has a plurality of printhead ICs mounted end to end along one side face. Optionally the printhead ICs are mounted to the side face via an interposed adhesive film having holes for fluid communication between the ink feed passages and the printhead ICs. 
         [0042]    Accordingly, in a fourth aspect the present invention provides a printhead for an inkjet printer, the printhead comprising: 
         [0043]    a printhead integrated circuit (IC), the printhead IC being elongate and having an array of nozzles for ejecting ink; 
         [0044]    a support structure for supporting the printhead IC and having ink outlets for supplying the array of nozzles with ink; wherein, 
         [0045]    the ink outlets are spaced along the printhead IC such that the ink outlet spacing decreases at the ends of the printhead IC. 
         [0046]    By increasing the number of ink outlets near the end regions, the ink supply is enhanced to compensate for the slower priming of the end nozzles. This, in turn, makes the whole nozzle array prime more consistently to avoid flooding and ink wastage from early priming nozzles (or alternatively, unprimed end nozzles). 
         [0047]    Optionally, the support structure supports a plurality of the printhead ICs configured in an end to end relationship, the support structure having a plurality of ink feed passages for supplying ink to the ink outlets such that at least some of the ink feed passages near a junction between ends of two of the printhead ICs, supplies ink to two of the ink outlets, the two ink outlets being on different sides of the junction. Optionally, the support structure has a molded ink manifold in which the ink feed passages are formed and a polymer film in which the ink outlets are formed, such that the polymer film is mounted to the molded ink manifold and the printhead ICs are mounted to the other side of the polymer film. Optionally, the printhead IC&#39;s have ink inlet channels on one side of a wafer substrate and the array of nozzles formed on the other side of the wafer substrate such that each of the ink inlet channels connects to at least one of the ink outlets. 
         [0048]    Optionally the support structure has a fluidic damper for damping pressure pulses in the ink being supplied to the printhead ICs. Optionally, the fluidic damper has an array of cavities for holding a volume of gas such that each cavity is a separate pocket of the gas. Optionally, each of the cavities is partially defined by an ink meniscus formed when the ink conduits of the support structure are primed with ink. 
         [0049]    Optionally, the ink manifold has a series in main channels extending parallel to the printhead ICs, the main channels supplying ink to the ink feed passages, and each of the cavities is a blind recess with an opening facing one or more of the main channels. Optionally, the opening of each of the blind recesses faces one of the main channels only. Optionally, the opening of each of the blind recesses of configured to inhibit ink filling the recess by capillary action. 
         [0050]    Optionally, the support structure has an inlet for connecting the ink conduits to an ink supply and an outlet for connecting the ink conduits to a waste ink outlet. Optionally, the openings to each respective cavity have an upstream edge and a downstream edge, the upstream edge contacting the ink before the downstream edge during initial priming of the main channels from the ink supply, and the upstream edge having a transition face between the conduit and the cavity interior, the transition face being configured to inhibit from filling the cavity and purging the gas by capillary action during initial priming of the ink conduit. 
         [0051]    Optionally, the printhead is a pagewidth printhead and the support structure is elongate with the inlet at one end and the outlet at the other end, and the main channels extend longitudinally along the support structure between the inlet and the outlet, and the ink feed passages join to one of the main channels along a wall of the main channel that is opposite the wall including the openings to the cavities. 
         [0052]    Optionally, the support structure is a liquid crystal polymer (LCP). Optionally the support structure is a two-part LCP molding with the channels and the feed passages formed in one part and the cavities formed in the other part. 
         [0053]    Accordingly, in a fifth aspect the present invention provides a detachable fluid coupling for establishing sealed fluid communication between an inkjet printhead and an ink supply; the detachable coupling comprising: 
         [0054]    a fixed valve member defining a valve seat; 
         [0055]    a sealing collar for sealing engagement with the valve seat; 
         [0056]    a resilient sleeve having one annular end fixed relative to the fixed valve member, and the other annular end engaging the sealing collar to bias it into sealing engagement with the valve seat; and, 
         [0057]    a conduit opening that is movable relative to the fixed valve member for engaging the sealing collar to unseal it from the valve seat; wherein, 
         [0058]    unsealing the sealing collar from the valve seat compresses the resilient sleeve such that an intermediate section of the sleeve displaces outwardly relative to the annular ends. 
         [0059]    With a resilient sleeve that buckles or folds outwardly, the diameter of the coupling is smaller that the conventional couplings that use an annular resilient element that biases the valve shut remaining residual tension. With a smaller outer diameter, the couplings for all the different ink colors can be positioned in a smaller more compact interface. 
         [0060]    Optionally, the intermediate section of the resilient sleeve is an annular fold to expand outwardly when the sleeve is axially compressed. Optionally, the resilient sleeve applies a restorative force to the sealing collar when the conduit opening is withdrawn such that the restorative force increases as the axial length increases such that a maximum restorative force is applied to the sealing collar when it is sealed against the valve seat. Optionally, the resilient sleeve connects to an inner diameter of the sealing collar. Optionally, both of the annular ends of the resilient sleeve are substantially the same size. 
         [0061]    Optionally, the sealing collar has resilient material where the conduit opening engages it so that a fluid tight seal forms upon such engagement. Optionally, the fluid tight seal between the conduit opening and the sealing collar forms before the sealing collar unseals from the valve seat. 
         [0062]    Optionally, the fixed valve member has a hollow section that forms part of a fluid flow path through the coupling when the coupling is open. Optionally the fixed valve member and the resilient sleeve are on a downstream side of the coupling and the conduit opening is on an upstream side. Optionally, the downstream side is part of a cartridge with a replaceable printhead and the upstream side is part of a printer in which the cartridge can be installed. 
         [0063]    Accordingly, in a sixth aspect the present invention provides a filter for an inkjet printer, the filter comprising: 
         [0064]    a chamber divided into an upstream section and a downstream section by a filter membrane; 
         [0065]    an inlet conduit for establishing fluid communication between an ink supply and the upstream section; and, 
         [0066]    an outlet conduit for establishing fluid communication between the downstream section and a printhead; wherein during use, 
         [0067]    at least part of the inlet conduit is elevated relative to the filter membrane. 
         [0068]    By elevating the inlet conduit relative to the filter membrane, it acts as a bubble trap to retain bubbles that would otherwise obstruct the filter. This allows the filter size to be reduced for a more compact overall design. 
         [0069]    Optionally, the chamber has an internal height and width corresponding to the dimensions of the filter membrane and a thickness that is substantially less that height and width dimensions. 
         [0070]    Configuring the chamber in this way keeps the overall volume to a minimum and places the filter membrane in a generally vertical plane. The buoyancy of any bubbles in the chamber will urge them closer to the top of the chamber and possibly back into the inlet conduit. This discourages bubbles from pinning to the upstream face of the filter membrane. 
         [0071]    Optionally, the outlet conduit connects to the downstream section at its point with the lowest elevation during use. If bubbles do start to obstruct the filter, they will obstruct the lowest areas of the chamber last. Optionally the filter membrane is rectangular and the inlet connects to the upstream section at one corner and the outlet conduit connects to the diagonally opposed corner. 
         [0072]    Optionally, the downstream section has a support formation for the filter membrane to bear against such that it remains spaced from an opposing wall of the downstream section. Optionally the opposing wall is also a wall that partially defines the upstream section of a like chamber housing a like filter member, such that a number of filters are configured side-by-side. 
         [0073]    Optionally, the filter is installed in a component of the inkjet printer that is intended to be periodically replaced. 
         [0074]    Optionally, the filter is installed in a cartridge with a pagewidth printhead. Optionally the cartridge has a detachable ink coupling upstream of the filter for connection to an ink supply. 
         [0075]    Accordingly, in a seventh aspect the present invention provides an ink coupling for establishing fluid communication between an inkjet printer and a replaceable cartridge for installation in the printer, the coupling comprising: 
         [0076]    a cartridge valve on the cartridge side of the coupling; and, 
         [0077]    a printer conduit on the printer side of the coupling, the cartridge valve and the printer conduit having complementary formations configured to form a coupling seal when brought into engagement; wherein, 
         [0078]    the cartridge valve is biased closed and configured to open when brought into engagement with the printer conduit; such that, 
         [0079]    upon disengagement, the coupling seal breaks after the cartridge valve closes, and an ink meniscus forms and recedes from the complementary formations as they separate, the cartridge valve having external surfaces configured so that the meniscus cleanly detaches from the printer conduit and only pins to the printer conduit surfaces. 
         [0080]    The invention keeps residual ink off the exterior of the cartridge valve by careful design of the external surfaces with respect to known receding contact angle of the ink meniscus. As the coupling seal breaks and the meniscus forms, the ink properties and hydrophilicity of the respective valve materials will determine where the meniscus stops moving and eventually pins itself. Knowing the ink properties and that the direction of disengagement, the valve materials and exterior design can make the meniscus pin to the printer conduits only. 
         [0081]    Optionally, at least one of the external surfaces of the cartridge valve has less hydrophilicity than at least one of the external surfaces on the printer conduit. Optionally, the cartridge engages from the printer by moving vertically downwards and disengages by moving vertically upwards. Optionally, upon engagement, the coupling seal forms before the cartridge valve and the printer valve opens. Optionally, the cartridge valve has a fixed valve member defining a valve seat and a sealing collar for sealing engagement with the valve seat, and a resilient sleeve having one annular end fixed relative to the fixed valve member, and the other annular end engaging the sealing collar to bias it into sealing engagement with the valve seat; and, 
         [0082]    the printer conduit has a conduit opening; such that, 
         [0083]    an axial end of the conduit opening and the sealing collar provide the complementary formations on the printer conduit and the cartridge valve respectively. 
         [0084]    Optionally, the conduit opening seals against the sealing collar before opening the cartridge valve. Optionally, the resilient sleeve and the sealing collar are integrally formed. Optionally, the resilient sleeve and sealing collar are silicone. Optionally, the fixed valve member is formed from poly(ethylene terephthalate) (PET). Optionally, the conduit opening is formed from poly(ethylene terephthalate) (PET). 
         [0085]    Optionally, the cartridge has a pagewidth printhead and the printer has an ink reservoir for supplying the printhead via the coupling. 
         [0086]    Accordingly, in an eighth aspect the present invention provides a printhead for an inkjet printer, the printhead comprising: 
         [0087]    a printhead integrated circuit (IC) having an array of nozzles for ejecting ink; and, 
         [0088]    a support structure for mounting the printhead IC within the printer, the support structure having ink conduits for supplying the array of nozzles with ink, the ink conduits have a weir formation to partially obstruct ink flow; wherein, 
         [0089]    when priming the printhead, the weir formation preferentially primes an upstream section the ink conduit. 
         [0090]    Using a weir downstream of areas that have a propensity to prime incorrectly can force them to prime more quickly or in preference to downstream sections. As long as the downstream section is one that reliably primes, albeit delayed by the weir, there is no disadvantage to priming the upstream section in preference. 
         [0091]    Optionally, the weir formation has a top profile configured to provide an anchor point for the meniscus of an advancing ink flow. Optionally, the upstream section has cavities in its uppermost surface that are intended to hold pockets of air after the printhead has been primed. Optionally, the cavities have openings defined in the uppermost surface of the upstream section, the upstream edge of each opening being curved and the downstream edge being relatively sharp so that ink flowing from the upstream direction does get drawn into the cavity by capillary action. Optionally the weir is positioned to momentarily anchor the meniscus of the advancing ink flow and divert it from contact the relatively sharp edge of the opening for one of the cavities. Optionally, the printhead is a cartridge configured for user removal replacement. Optionally, the cartridge is unprimed when installed and subsequently primed by a pump in the printer. 
         [0092]    Accordingly, in a ninth aspect the present invention provides a printhead for an inkjet printer, the printhead comprising: 
         [0093]    a printhead integrated circuit (IC) having an array of nozzles for ejecting ink; and, 
         [0094]    a support structure for mounting the printhead IC within the printer, the support structure having ink conduits for supplying the array of nozzles with ink, the ink conduits have a meniscus anchor for pinning part of an advancing meniscus of ink to divert the advancing meniscus from a path it would otherwise take. 
         [0095]    If a printhead consistently fails to prime correctly because a meniscus pins at one or more points, then the advancing meniscus can be directed so that it does not contact these critical points. Deliberately incorporating a discontinuity into an ink conduit immediately upstream of the problem area can temporarily pin to the meniscus and skew it to one side of the conduit and away from the undesirable pinning point. Once flow has been initiated into the side branch or downstream of the undesirable pinning point, it is not necessary for the anchor to hold the ink meniscus any longer and priming can continue. 
         [0096]    Optionally, the meniscus anchor is an abrupt protrusion into the ink conduit. Optionally, the meniscus anchor is a weir formation to partially obstruct ink flow such that, when priming the printhead, the weir formation preferentially primes an upstream section the ink conduit. 
         [0097]    Optionally, the upstream section has cavities in its uppermost surface that are intended to hold pockets of air after the printhead has been primed. Optionally, the cavities have openings defined in the uppermost surface of the upstream section, the upstream edge of each opening being curved and the downstream edge being relatively sharp so that ink flowing from the upstream direction does get drawn into the cavity by capillary action. Optionally the weir is positioned to momentarily anchor the meniscus of the advancing ink flow and divert it from contact the relatively sharp edge of the opening for one of the cavities. Optionally, the printhead is a cartridge configured for user removal replacement. Optionally, the cartridge is unprimed when installed and subsequently primed by a pump in the printer. 
         [0098]    Accordingly, in a tenth aspect the present invention provides a printhead for an inkjet printer, the inkjet printer having a print engine controller for receiving print data and sending it to the printhead, the printhead comprising: 
         [0099]    a printhead IC with an array of nozzles for ejecting ink; 
         [0100]    a support structure for mounting the printhead IC in the printer adjacent a paper path, the printhead IC being mounted on a face of the support structure that, in use, faces the paper path; 
         [0101]    a flexible printed circuit board (flex PCB) having drive circuitry for operating the array of nozzles on the printhead IC, the drive circuitry having circuit components connected by traces in the flex PCB, the flex PCB also having contacts for receiving print data from the print engine controller, the flex PCB at the contacts being mounted to the support structure on a face that does not face the paper path such that the flex PCB extends through a bent section between the printhead IC and the contacts; wherein, 
         [0102]    the printhead IC and the circuit components are adjacent each other and separated from the contacts by the bent section of the flex PCB. 
         [0103]    Optionally, the support structure has a curved surface to support the bent section of the flex PCB. The curved surface reduces the likelihood of trace cracking by holding the flex PCB at a set radius rather than allowing the flex to follow an irregular curve in the bent section, and thereby risking localized points of high stress on the traces. 
         [0104]    Optionally the flex PCB is anchored to the support structure at the circuit components. Optionally the circuit components include capacitors that discharge during a firing sequence of the nozzles on the printhead IC. Optionally the support structure is a liquid crystal polymer (LCP) molding. LCP can be molded such that its coefficient of thermal expansion (CTE) is roughly the same as that of the silicon substrate in the printhead IC. 
         [0105]    Optionally the LCP molding has ink conduits for supplying ink to the printhead IC. Optionally the ink conduits lead to outlets in the face of the LCP molding on which the printhead IC is mounted. 
         [0106]    Optionally the printhead is a pagewidth printhead. Optionally the support structure has a cartridge bearing section located opposite the contacts, and a force transfer member extending from the contacts to cartridge bearing section such that when installed in the printer, pressure from the printer&#39;s complementary contacts is transferred directly to the cartridge bearing section via the force transfer member. Optionally the bearing section includes a locating formation for engagement with a complementary formation on the printer. Optionally, the locating formation is a ridge with a rounded distal end such that the cartridge can be rotated into position once the ridge has engaged the printer. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0107]    Embodiments of the invention will now be described by way of example only with reference to the accompanying drawings, in which: 
           [0108]      FIG. 1  is a front and side perspective of a printer embodying the present invention; 
           [0109]      FIG. 2  shows the printer of  FIG. 1  with the front face in the open position; 
           [0110]      FIG. 3  shows the printer of  FIG. 2  with the printhead cartridge removed; 
           [0111]      FIG. 4  shows the printer of  FIG. 3  with the outer housing removed; 
           [0112]      FIG. 5  shows the printer of  FIG. 3  with the outer housing removed and printhead cartridge installed; 
           [0113]      FIG. 6  is a schematic representation of the printer&#39;s fluidic system; 
           [0114]      FIG. 7  is a top and front perspective of the printhead cartridge; 
           [0115]      FIG. 8  is a top and front perspective of the printhead cartridge in its protective cover; 
           [0116]      FIG. 9  is a top and front perspective of the printhead cartridge removed from its protective cover; 
           [0117]      FIG. 10  is a bottom and front perspective of the printhead cartridge; 
           [0118]      FIG. 11  is a bottom and rear perspective of the printhead cartridge; 
           [0119]      FIG. 12  shows the elevations of all sides of the printhead cartridge; 
           [0120]      FIG. 13  is an exploded perspective of the printhead cartridge; 
           [0121]      FIG. 14  is a transverse section through the ink inlet coupling of the printhead cartridge; 
           [0122]      FIG. 15  is an exploded perspective of the ink inlet and filter assembly; 
           [0123]      FIG. 16  is a section view of the cartridge valve engaged with the printer valve; 
           [0124]      FIG. 17  is a perspective of the LCP molding and flex PCB; 
           [0125]      FIG. 18  is an enlargement of inset A shown in  FIG. 17 ; 
           [0126]      FIG. 19  is an exploded bottom perspective of the LCP/flex PCB/printhead IC assembly; 
           [0127]      FIG. 20  is an exploded top perspective of the LCP/flex PCB/printhead IC assembly; 
           [0128]      FIG. 21  is an enlarged view of the underside of the LCP/flex PCB/printhead IC assembly; 
           [0129]      FIG. 22  shows the enlargement of  FIG. 21  with the printhead ICs and the flex PCB removed; 
           [0130]      FIG. 23  shows the enlargement of  FIG. 22  with the printhead IC attach film removed; 
           [0131]      FIG. 24  shows the enlargement of  FIG. 23  with the LCP channel molding removed; 
           [0132]      FIG. 25  shows the printhead ICs with back channels and nozzles superimposed on the ink supply passages; 
           [0133]      FIG. 26  in an enlarged transverse perspective of the LCP/flex PCB/printhead IC assembly; 
           [0134]      FIG. 27  is a plan view of the LCP channel molding; 
           [0135]      FIGS. 28A and 28B  are schematic section views of the LCP channel molding priming without a weir; 
           [0136]      FIGS. 29A ,  29 B and  29 C are schematic section views of the LCP channel molding priming with a weir; 
           [0137]      FIG. 30  in an enlarged transverse perspective of the LCP molding with the position of the contact force and the reaction force; 
           [0138]      FIG. 31  shows a reel of the IC attachment film; 
           [0139]      FIG. 32  shows a section of the IC attach film between liners; and 
           [0140]      FIG. 33  is a partial section view showing the laminate structure of the attachment film. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Overview 
       [0141]      FIG. 1  shows a printer  2  embodying the present invention. The main body  4  of the printer supports a media feed tray  14  at the back and a pivoting face  6  at the front.  FIG. 1  shows the pivoting face  6  closed such that the display screen  8  is its upright viewing position. Control buttons  10  extend from the sides of the screen  8  for convenient operator input while viewing the screen. To print, a single sheet is drawn from the media stack  12  in the feed tray  14  and fed past the printhead (concealed within the printer). The printed sheet  16  is delivered through the printed media outlet slot  18 . 
         [0142]      FIG. 2  shows the pivoting front face  6  open to reveal the interior of the printer  2 . Opening the front face of the printer exposes the printhead cartridge  96  installed within. The printhead cartridge  96  is secured in position by the cartridge engagement cams  20  that push it down to ensure that the ink coupling (described later) is fully engaged and the printhead ICs (described later) are correctly positioned adjacent the paper feed path. The cams  20  are manually actuated by the release lever  24 . The front face  6  will not close, and hence the printer will not operate, until the release lever  24  is pushed down to fully engage the cams. Closing the pivoting face  6  engages the printer contacts  22  with the cartridge contacts  104 . 
         [0143]      FIG. 3  shows the printer  2  with the pivoting face  6  open and the printhead cartridge  96  removed. With the pivoting face  6  tilted forward, the user pulls the cartridge release lever  24  up to disengage the cams  20 . This allows the handle  26  on the cartridge  96  to be gripped and pulled upwards. The upstream and downstream ink couplings  112 A and  112 B disengage from the printer conduits  142 . This is described in greater detail below. To install a fresh cartridge, the process is reversed. New cartridges are shipped and sold in an unprimed condition. So to ready the printer for printing, the active fluidics system (described below) uses a downstream pump to prime the cartridge and printhead with ink. 
         [0144]    In  FIG. 4 , the outer casing of the printer  2  has been removed to reveal the internals. A large ink tank  60  has separate reservoirs for all four different inks. The ink tank  60  is itself a replaceable cartridge that couples to the printer upstream of the shut off valve  66  (see  FIG. 6 ). There is also a sump  92  for ink drawn out of the cartridge  96  by the pump  62 . The printer fluidics system is described in detail with reference to  FIG. 6 . Briefly, ink from the tank  60  flows through the upstream ink lines  84  to the shut off valves  66  and on to the printer conduits  142 . As shown in  FIG. 5 , when the cartridge  96  is installed, the pump  62  (driven by motor  196 ) can draw ink into the LCP molding  64  (see  FIGS. 6 and 17  to  20 ) so that the printhead ICs  68  (again, see  FIGS. 6 and 17  to  20 ) prime by capillary action. Excess ink drawn by the pump  62  is fed to a sump  92  housed with the ink tanks  60 . 
         [0145]    The total connector force between the cartridge contacts  104  and the printer contacts  22  is relatively high because of the number of contacts used. In the embodiment shown, the total contact force is 45 Newtons. This load is enough to flex and deform the cartridge. Turning briefly to  FIG. 30 , the internal structure of the chassis molding  100  is shown. The bearing surface  28  shown in  FIG. 3  is schematically shown in  FIG. 30 . The compressive load of the printer contacts on the cartridge contacts  104  is represented with arrows. The reaction force at the bearing surface  28  is likewise represented with arrows. To maintain the structural integrity of the cartridge  96 , the chassis molding  100  has a structural member  30  that extends in the plane of the connector force. To keep the reaction force acting in the plane of the connector force, the chassis also has a contact rib  32  that bears against the bearing surface  28 . This keeps the load on the structural member  30  completely compressive to maximize the stiffness of the cartridge and minimize any flex. 
       Print Engine Pipeline 
       [0146]    The print engine pipeline is a reference to the printer&#39;s processing of print data received from an external source and outputted to the printhead for printing. The print engine pipeline is described in detail in U.S. Ser. No. 11/014,769 (RRC001US) filed Dec. 20, 2004, the disclosure of which is incorporated herein by reference. 
       Fluidic System 
       [0147]    Traditionally printers have relied on the structure and components within the printhead, cartridge and ink lines to avoid fluidic problems. Some common fluidic problems are deprimed or dried nozzles, outgassing bubble artifacts and color mixing from cross contamination. Optimizing the design of the printer components to avoid these problems is a passive approach to fluidic control. Typically, the only active component used to correct these were the nozzle actuators themselves. However, this is often insufficient and or wastes a lot of ink in the attempt to correct the problem. The problem is exacerbated in pagewidth printheads because of the length and complexity of the ink conduits supplying the printhead ICs. 
         [0148]    The Applicant has addressed this by developing an active fluidic system for the printer. Several such systems are described in detail in U.S. Ser. No. 11/677,049 (Our Docket SBF006US) the contents of which are incorporated herein by reference.  FIG. 6  shows one of the single pump implementations of the active fluidic system which would be suitable for use with the printhead described in the present specification. 
         [0149]    The fluidic architecture shown in  FIG. 6  is a single ink line for one color only. A color printer would have separate lines (and of course separate ink tanks  60 ) for each ink color. As shown in  FIG. 6 , this architecture has a single pump  62  downstream of the LCP molding  64 , and a shut off valve  66  upstream of the LCP molding. The LCP molding supports the printhead IC&#39;s  68  via the adhesive IC attach film  174  (see  FIG. 25 ). The shut off valve  66  isolates the ink in the ink tank  60  from the printhead IC&#39;s  66  whenever the printer is powered down. This prevents any color mixing at the printhead IC&#39;s  68  from reaching the ink tank  60  during periods of inactivity. These issues are discussed in more detail in the cross referenced specification U.S. Ser. No. 11/677,049 (our Docket SBF006US). 
         [0150]    The ink tank  60  has a venting bubble point pressure regulator  72  for maintaining a relatively constant negative hydrostatic pressure in the ink at the nozzles. Bubble point pressure regulators within ink reservoirs are comprehensively described in co-pending U.S. Ser. No. 11/640,355 (Our Docket RMC007US) incorporated herein by reference. However, for the purposes of this description the regulator  72  is shown as a bubble outlet  74  submerged in the ink of the tank  60  and vented to atmosphere via sealed conduit  76  extending to an air inlet  78 . As the printhead IC&#39;s  68  consume ink, the pressure in the tank  60  drops until the pressure difference at the bubble outlet  74  sucks air into the tank. This air forms a forms a bubble in the ink which rises to the tank&#39;s headspace. This pressure difference is the bubble point pressure and will depend on the diameter (or smallest dimension) of the bubble outlet  74  and the Laplace pressure of the ink meniscus at the outlet which is resisting the ingress of the air. 
         [0151]    The bubble point regulator uses the bubble point pressure needed to generate a bubble at the submerged bubble outlet  74  to keep the hydrostatic pressure at the outlet substantially constant (there are slight fluctuations when the bulging meniscus of air forms a bubble and rises to the headspace in the ink tank). If the hydrostatic pressure at the outlet is at the bubble point, then the hydrostatic pressure profile in the ink tank is also known regardless of how much ink has been consumed from the tank. The pressure at the surface of the ink in the tank will decrease towards the bubble point pressure as the ink level drops to the outlet. Of course, once the outlet  74  is exposed, the head space vents to atmosphere and negative pressure is lost. The ink tank should be refilled, or replaced (if it is a cartridge) before the ink level reaches the bubble outlet  74 . 
         [0152]    The ink tank  60  can be a fixed reservoir that can be refilled, a replaceable cartridge or (as disclosed in RRC001US incorporated by reference) a refillable cartridge. To guard against particulate fouling, the outlet  80  of the ink tank  60  has a coarse filter  82 . The system also uses a fine filter at the coupling to the printhead cartridge. As filters have a finite life, replacing old filters by simply replacing the ink cartridge or the printhead cartridge is particularly convenient for the user. If the filters are separate consumable items, regular replacement relies on the user&#39;s diligence. 
         [0153]    When the bubble outlet  74  is at the bubble point pressure, and the shut off valve  66  is open, the hydrostatic pressure at the nozzles is also constant and less than atmospheric. However, if the shut off valve  66  has been closed for a period of time, outgassing bubbles may form in the LCP molding  64  or the printhead IC&#39;s  68  that change the pressure at the nozzles. Likewise, expansion and contraction of the bubbles from diurnal temperature variations can change the pressure in the ink line  84  downstream of the shut off valve  66 . Similarly, the pressure in the ink tank can vary during periods of inactivity because of dissolved gases coming out of solution. 
         [0154]    The downstream ink line  86  leading from the LCP  64  to the pump  62  can include an ink sensor  88  linked to an electronic controller  90  for the pump. The sensor  88  senses the presence or absence of ink in the downstream ink line  86 . Alternatively, the system can dispense with the sensor  88 , and the pump  62  can be configured so that it runs for an appropriate period of time for each of the various operations. This may adversely affect the operating costs because of increased ink wastage. 
         [0155]    The pump  62  feeds into a sump  92  (when pumping in the forward direction). The sump  92  is physically positioned in the printer so that it is less elevated than the printhead ICs  68 . This allows the column of ink in the downstream ink line  86  to ‘hang’ from the LCP  64  during standby periods, thereby creating a negative hydrostatic pressure at the printhead ICs  68 . A negative pressure at the nozzles draws the ink meniscus inwards and inhibits color mixing. Of course, the peristaltic pump  62  needs to be stopped in an open condition so that there is fluid communication between the LCP  64  and the ink outlet in the sump  92 . 
         [0156]    Pressure differences between the ink lines of different colors can occur during periods of inactivity. Furthermore, paper dust or other particulates on the nozzle plate can wick ink from one nozzle to another. Driven by the slight pressure differences between each ink line, color mixing can occur while the printer is inactive. The shut off valve  66  isolates the ink tank  60  from the nozzle of the printhead IC&#39;s  68  to prevent color mixing extending up to the ink tank  60 . Once the ink in the tank has been contaminated with a different color, it is irretrievable and has to be replaced. 
         [0157]    The capper  94  is a printhead maintenance station that seals the nozzles during standby periods to avoid dehydration of the printhead ICs  68  as well as shield the nozzle plate from paper dust and other particulates. The capper  94  is also configured to wipe the nozzle plate to remove dried ink and other contaminants Dehydration of the printhead ICs  68  occurs when the ink solvent, typically water, evaporates and increases the viscosity of the ink. If the ink viscosity is too high, the ink ejection actuators fail to eject ink drops. Should the capper seal be compromised, dehydrated nozzles can be a problem when reactivating the printer after a power down or standby period. 
         [0158]    The problems outlined above are not uncommon during the operative life of a printer and can be effectively corrected with the relatively simple fluidic architecture shown in  FIG. 6 . It also allows the user to initially prime the printer, deprime the printer prior to moving it, or restore the printer to a known print ready state using simple trouble-shooting protocols. Several examples of these situations are described in detail in the above referenced U.S. Ser. No. 11/677,049 (Our Docket SBF006US). 
       Printhead Cartridge 
       [0159]    The printhead cartridge  96  is shown in  FIGS. 7 to 16A .  FIG. 7  shows the cartridge  96  in its assembled and complete form. The bulk of the cartridge is encased in the cartridge chassis  100  and the chassis lid  102 . A window in the chassis  100  exposes the cartridge contacts  104  that receive data from the print engine controller in the printer. 
         [0160]      FIGS. 8 and 9  show the cartridge  96  with its snap on protective cover  98 . The protective cover  98  prevents damaging contact with the electrical contacts  104  and the printhead IC&#39;s  68  (see  FIG. 10 ). The user can hold the top of the cartridge  96  and remove the protective cover  98  immediately prior to installation in the printer. 
         [0161]      FIG. 10  shows the underside and ‘back’ (with respect to the paper feed direction) of the printhead cartridge  96 . The printhead contacts  104  are conductive pads on a flexible printed circuit board  108  that wraps around a curved support surface (discussed below in the description relating to the LCP moulding) to a line of wire bonds  110  at one side if the printhead IC&#39;s  68 . On the other side of the printhead IC&#39;s  68  is a paper shield  106  to prevent direct contact with the media substrate. 
         [0162]      FIG. 11  shows the underside and the ‘front’ of the printhead cartridge  96 . The front of the cartridge has two ink couplings  112 A and  112 B at either end. Each ink coupling has four cartridge valves  114 . When the cartridge is installed in the printer, the ink couplings  112 A and  112 B engage complementary ink supply interfaces (described in more detail below). The ink supply interfaces have printer conduits  142  which engage and open the cartridge valves  114 . One of the ink couplings  112 A is the upstream ink coupling and the other is the downstream coupling  112 B. The upstream coupling  112 A establishes fluid communication between the printhead IC&#39;s  68  and the ink supply  60  (see  FIG. 6 ) and the downstream coupling  112 B connects to the sump  92  (refer  FIG. 6  again). 
         [0163]    The various elevations of the printhead cartridge  96  are shown in  FIG. 12 . The plan view of the cartridge  96  also shows the location of the section views shown in  FIGS. 14 ,  15  and  16 . 
         [0164]      FIG. 13  is an exploded perspective of the cartridge  96 . The LCP molding  64  attaches to the underside of the cartridge chassis  100 . In turn the flex PCB  108  attaches to the underside of the LCP molding  64  and wraps around one side to expose the printhead contacts  104 . An inlet manifold and filter  116  and outlet manifold  118  attach to the top of the chassis  100 . The inlet manifold and filter  116  connects to the LCP inlets  122  via elastomeric connectors  120 . Likewise the LCP outlets  124  connect to the outlet manifold  118  via another set of elastomeric connectors  120 . The chassis lid  102  encases the inlet and outlet manifolds in the chassis  100  from the top and the removable protective cover  98  snaps over the bottom to protect the contacts  104  and the printhead IC&#39;s (see  FIG. 11 ). 
       Inlet and Filter Manifold 
       [0165]      FIG. 14  is an enlarged section view taken along line  14 - 14  of  FIG. 12 . It shows the fluid path through one of the cartridge valves  114  of the upstream coupling  112 A to the LCP molding  64 . The cartridge valve  114  has an elastomeric sleeve  126  that is biased into sealing engagement with a fixed valve member  128 . The cartridge valve  114  is opened by the printer conduit  142  (see  FIG. 16 ) by compressing the elastomeric sleeve  126  such that it unseats from the fixed valve member  128  and allows ink to flow up to a roof channel  138  along the top of the inlet and filter manifold  116 . The roof channel  138  leads to an upstream filter chamber  132  that has one wall defined by a filter membrane  130 . Ink passes through the filter membrane  130  into the downstream filter chamber  134  and out to the LCP inlet  122 . From there filtered ink flows along the LCP main channels  136  to feed into the printhead IC&#39;s (not shown). 
         [0166]    Particular features and advantages of the inlet and filter manifold  116  will now be described with reference to  FIG. 15 . The exploded perspective of  FIG. 15  best illustrates the compact design of the inlet and filter manifold  116 . There are several aspects of the design that contribute to its compact form. Firstly, the cartridge valves are spaced close together. This is achieved by departing from the traditional configuration of self-sealing ink valves. Previous designs also used an elastomeric member biased into sealing engagement with a fixed member. However, the elastomeric member was either a solid shape that the ink would flow around, or in the form of a diaphragm if the ink flowed through it. 
         [0167]    In a cartridge coupling, it is highly convenient for the cartridge valves to automatically open upon installation. This is most easily and cheaply provided by a coupling in which one valve has an elastomeric member which is engaged by a rigid member on the other valve. If the elastomeric member is in a diaphragm form, it usually holds itself against the central rigid member under tension. This provides an effective seal and requires relatively low tolerances. However, it also requires the elastomer element to have a wide peripheral mounting. The width of the elastomer will be a trade-off between the desired coupling force, the integrity of the seal and the material properties of the elastomer used. 
         [0168]    As best shown in  FIG. 16 , the cartridge valves  114  of the present invention use elastomeric sleeves  126  that seal against the fixed valve member  128  under residual compression. The valve  114  opens when the cartridge is installed in the printer and the conduit end  148  of the printer valve  142  further compresses the sleeve  126 . The collar  146  unseals from the fixed valve member  128  to connect the LCP  64  into the printer fluidic system (see  FIG. 6 ) via the upstream and downstream ink coupling  112 A and  112 B. The sidewall of the sleeve is configured to bulge outwardly as collapsing inwardly can create a flow obstruction. As shown in  FIG. 16 , the sleeve  126  has a line of relative weakness around its mid-section that promotes and directs the buckling process. This reduces the force necessary to engage the cartridge with the printer, and ensures that the sleeve buckles outwardly. 
         [0169]    The coupling is configured for ‘no-drip’ disengagement of the cartridge from the printer. As the cartridge is pulled upwards from the printer the elastomeric sleeve  126  pushes the collar  146  to seal against the fixed valve member  128 . Once the sleeve  126  has sealed against the valve member  128  (thereby sealing the cartridge side of the coupling), the sealing collar  146  lifts together with the cartridge. This unseals the collar  146  from the end of the conduit  148 . As the seal breaks an ink meniscus forms across the gap between the collar and the end of the conduit  148 . The shape of the end of the fixed valve member  128  directs the meniscus to travel towards the middles of its bottom surface instead of pinning to a point. At the middle of the rounded bottom of the fixed valve member  128 , the meniscus is driven to detach itself from the now almost horizontal bottom surface. To achieve the lowest possible energy state, the surface tension drives the detachment of the meniscus from the fixed valve member  128 . The bias to minimize meniscus surface area is strong and so the detachment is complete with very little, if any, ink remaining on the cartridge valve  114 . Any remaining ink is not enough a drop that can drip and stain prior to disposal of the cartridge. 
         [0170]    When a fresh cartridge is installed in the printer, the air in conduit  150  will be entrained into the ink flow  152  and ingested by the cartridge. In light of this, the inlet manifold and filter assembly have a high bubble tolerance. Referring back to  FIG. 15 , the ink flows through the top of the fixed valve member  128  and into the roof channel  138 . Being the most elevated point of the inlet manifold  116 , the roof channels can trap the bubbles. However, bubbles may still flow into the filter inlets  158 . In this case, the filter assembly itself is bubble tolerant. 
         [0171]    Bubbles on the upstream side of the filter member  130  can affect the flow rate—they effectively reduce the wetted surface area on the dirty side of the filter membrane  130 . The filter membranes have a long rectangular shape so even if an appreciable number of bubbles are drawn into the dirty side of the filter, the wetted surface area remains large enough to filter ink at the required flow rate. This is crucial for the high speed operation offered by the present invention. 
         [0172]    While the bubbles in the upstream filter chamber  132  can not cross the filter membrane  130 , bubbles from outgassing may generate bubbles in the downstream filter chamber  134 . The filter outlet  156  is positioned at the bottom of the downstream filter chamber  134  and diagonally opposite the inlet  158  in the upstream chamber  132  to minimize the effects of bubbles in either chamber on the flow rate. 
         [0173]    The filters  130  for each color are vertically stacked closely side-by-side. The partition wall  162  partially defines the upstream filter chamber  132  on one side, and partially defines the downstream chamber  134  of the adjacent color on the other side. As the filter chambers are so thin (for compact design), the filter membrane  130  can be pushed against the opposing wall of the downstream filter chamber  134 . This effectively reduces the surface are of the filter membrane  130 . Hence it is detrimental to maximum flowrate. To prevent this, the opposing wall of the downstream chamber  134  has a series of spacer ribs  160  to keep the membrane  130  separated from the wall. 
         [0174]    Positioning the filter inlet and outlet at diagonally opposed corners also helps to purge the system of air during the initial prime of the system. 
         [0175]    To reduce the risk of particulate contamination of the printhead, the filter membrane  130  is welded to the downstream side of a first partition wall before the next partition wall  162  is welded to the first partition wall. In this way, any small pieces of filter membrane  130  that break off during the welding process, will be on the ‘dirty’ side of the filter  130 . 
       LCP Molding/Flex PCB/Printhead ICS 
       [0176]    The LCP molding  64 , flex PCB  108  and printhead ICs  68  assembly are shown in  FIGS. 17 to 33 .  FIG. 17  is a perspective of the underside of the LCP molding  64  with the flex PCB and printhead ICs  68  attached. The LCP molding  64  is secured to the cartridge chassis  100  through coutersunk holes  166  and  168 . Hole  168  is an obround hole to accommodate any miss match in coefficients of thermal expansion (CTE) without bending the LCP. The printhead ICs  68  are arranged end to end in a line down the longitudinal extent of the LCP molding  64 . The flex PCB  108  is wire bonded at one edge to the printhead ICs  68 . The flex PCB  108  also secures to the LCP molding at the printhead IC edge as well as at the cartridge contacts  104  edge. Securing the flex PCB at both edges keeps it tightly held to the curved support surface  170  (see  FIG. 19 ). This ensures that the flex PCB does not bend to a radius that is tighter than specified minimum, thereby reducing the risk that the conductive tracks through the flex PCB will fracture. 
         [0177]      FIG. 18  is an enlarged view of Inset A shown in  FIG. 17 . It shows the line of wire bonding contacts  164  along the side if the flex PCB  108  and the line of printhead ICs  68 . 
         [0178]      FIG. 19  is an exploded perspective of the LCP/flex/printhead IC assembly showing the underside of each component.  FIG. 20  is another exploded perspective, this time showing the topside of the components. The LCP molding  64  has an LCP channel molding  176  sealed to its underside. The printhead ICs  68  are attached to the underside of the channel molding  176  by adhesive IC attach film  174 . On the topside of the LCP channel molding  176  are the LCP main channels  184 . These are open to the ink inlet  122  and ink outlet  124  in the LCP molding  64 . At the bottom of the LCP main channels  184  are a series of ink supply passages  182  leading to the printhead ICs  68 . The adhesive IC attach film  174  has a series of laser drilled supply holes  186  so that the attachment side of each printhead IC  68  is in fluid communication with the ink supply passages  182 . The features of the adhesive IC attach film are described in detail below with reference to  FIGS. 31 to 33 . 
         [0179]    The LCP molding  64  has recesses  178  to accommodate electronic components  180  in the drive circuitry on the flex PCB  108 . For optimal electrical efficiency and operation, the cartridge contacts  104  on the PCB  108  should be close to the printhead ICs  68 . However, to keep the paper path adjacent the printhead straight instead of curved or angled, the cartridge contacts  104  need to be on the side of the cartridge  96 . The conductive paths in the flex PCB are known as traces. As the flex PCB must bend around a corner, the traces can crack and break the connection. To combat this, the trace can be bifurcated prior to the bend and then reunited after the bend. If one branch of the bifurcated section cracks, the other branch maintains the connection. Unfortunately, splitting the trace into two and then joining it together again can give rise to electro-magnetic interference problems that create noise in the circuitry. 
         [0180]    Making the traces wider is not an effective solution as wider traces are not significantly more crack resistant. Once the crack has initiated in the trace, it will propagate across the entire width relatively quickly and easily. Careful control of the bend radius is more effective at minimizing trace cracking, as is minimizing the number of traces that cross the bend in the flex PCB. 
         [0181]    Pagewidth printheads present additional complications because of the large array of nozzles that must fire in a relatively short time. Firing many nozzles at once places a large current load on the system. This can generate high levels of inductance through the circuits which can cause voltage dips that are detrimental to operation. To avoid this, the flex PCB has a series of capacitors that discharge during a nozzle firing sequence to relieve the current load on the rest of the circuitry. Because of the need to keep a straight paper path past the printhead ICs, the capacitors are traditionally attached to the flex PCB near the contacts on the side of the cartridge. Unfortunately, they create additional traces that risk cracking in the bent section of the flex PCB. 
         [0182]    This is addressed by mounting the capacitors  180  (see  FIG. 20 ) closely adjacent the printhead ICs  68  to reduce the chance of trace fracture. The paper path remains linear by recessing the capacitors and other components into the LCP molding  64 . The relatively flat surface of the flex PCB  108  downstream of the printhead ICs  68  and the paper shield  172  mounted to the ‘front’ (with respect to the feed direction) of the cartridge  96  minimize the risk of paper jams. 
         [0183]    Isolating the contacts from the rest of the components of the flex PCB minimizes the number of traces that extend through the bent section. This affords greater reliability as the chances of cracking reduce. Placing the circuit components next to the printhead IC means that the cartridge needs to be marginally wider and this is detrimental to compact design. However, the advantages provided by this configuration outweigh any drawbacks of a slightly wider cartridge. Firstly, the contacts can be larger as there are no traces from the components running in between and around the contacts. With larger contacts, the connection is more reliable and better able to cope with fabrication inaccuracies between the cartridge contacts and the printer-side contacts. This is particularly important in this case, as the mating contacts rely on users to accurately insert the cartridge. 
         [0184]    Secondly, the edge of the flex PCB that wire bonds to the side of the printhead IC is not under residual stress and trying to peel away from the bend radius. The flex can be fixed to the support structure at the capacitors and other components so that the wire bonding to the printhead IC is easier to form during fabrication and less prone to cracking as it is not also being used to anchor the flex. 
         [0185]    Thirdly, the capacitors are much closer to the nozzles of the printhead IC and so the electro-magnetic interference generated by the discharging capacitors is minimized. 
         [0186]      FIG. 21  is an enlargement of the underside of the printhead cartridge  96  showing the flex PCB  108  and the printhead ICs  68 . The wire bonding contacts  164  of the flex PCB  108  run parallel to the contact pads of the printhead ICs  68  on the underside of the adhesive IC attach film  174 .  FIG. 22  shows  FIG. 21  with the printhead ICs  68  and the flex PCB removed to reveal the supply holes  186 . The holes are arranged in four longitudinal rows. Each row delivers ink of one particular color and each row aligns with a single channel in the back of each printhead IC. 
         [0187]      FIG. 23  shows the underside of the LCP channel molding  176  with the adhesive IC attach film  174  removed. This exposes the ink supply passages  182  that connect to the LCP main channels  184  (see  FIG. 20 ) formed in the other side of the channel molding  176 . It will be appreciated that the adhesive IC attach film  174  partly defines the supply passages  182  when it is stuck in place. It will also be appreciated that the attach film must be accurately positioned, as the individual supply passages  182  must align with the supply holes  186  laser drilled through the film  174 . 
         [0188]      FIG. 24  shows the underside of the LCP molding with the LCP channel molding removed. This exposes the array of blind cavities  200  that contain air when the cartridge is primed with ink in order to damp any pressure pulses. This is discussed in greater detail below. 
       Printhead IC Attach Film 
       [0189]    Turning briefly to  FIGS. 31 to 33 , the adhesive IC attachment film is described in more detail. The film  174  is laser drilled and wound into a reel  198  for convenient incorporation in the printhead cartridge  96 . For the purposes of handling and storage, the film  174  is two protective liners on either side. One is the existing liner  188  that is attached to the film prior to laser drilling. The other is a replacement liner  192  added after the drilling operation. The section of film  174  shown in  FIG. 32  has some of the existing liner  188  removed to expose the supply holes  186 . The replacement liner  192  on the other side of the film is added after the supply holes  186  have been laser drilled. 
         [0190]      FIG. 33  shows the laminate structure of the film  174 . The central web  190  provides the strength for the laminate. On either side is an adhesive layer  194 . The adhesive layers  194  are covered with liners. The laser drilling forms holes  186  that extend from a first side of the film  174  and terminate somewhere in the liner  188  in the second side. The foraminous liner on the first side is removed and replaced with a replacement liner  192 . The strip of film is then wound into a reel  198  (see  FIG. 31 ) for storage and handling prior to attachment. When the printhead cartridge is assembled, suitable lengths are drawn from the reel  198 , the liners removed and adhered to the underside of the LCP molding  64  such that the holes  186  are in registration with the correct ink supply passages  182  (see  FIG. 25 ). 
       Enhanced Ink Supply To Printhead IC Ends 
       [0191]      FIG. 25  shows the printhead ICs  68 , superimposed on the ink supply holes  186  through the adhesive IC attach film  174 , which are in turn superimposed on the ink supply passages  182  in the underside of the LCP channel molding  176 . Adjacent printhead ICs  68  are positioned end to end on the bottom of the LCP channel molding  176  via the attach film  174 . At the junction between adjacent printhead ICs  68 , one of the ICs  68  has a ‘drop triangle’  206  portion of nozzles in rows that are laterally displaced from the corresponding row in the rest of the nozzle array  220 . This allows the edge of the printing from one printhead IC to be contiguous with the printing from the adjacent printhead IC. By displacing the drop triangle  206  of nozzles, the spacing (in a direction perpendicular to media feed) between adjacent nozzles remains unchanged regardless of whether the nozzles are on the same IC or either side of the junction on different ICs. This requires precise relative positioning of the adjacent printhead ICs  68 , and the fiducial marks  204  are used to achieve this. The process can be time consuming but avoids artifacts in the printed image. 
         [0192]    Unfortunately, some of the nozzles at the ends of a printhead IC  68  can be starved of ink relative to the bulk of the nozzles in the rest of the array  220 . For example, the nozzles  222  can be supplied with ink from two ink supply holes. Ink supply hole  224  is the closest. However, if there is an obstruction or particularly heavy demand from nozzles to the left of the hole  224 , the supply hole  226  is also proximate to the nozzles at  222 , so there is little chance of these nozzles depriming from ink starvation. 
         [0193]    In contrast, the nozzles  214  at the end of the printhead IC  68  would only be in fluid communication with the ink supply hole  216  were it not for the ‘additional’ ink supply hole  210  placed at the junction between the adjacent ICs  68 . Having the additional ink supply hole  210  means that none of the nozzles are so remote from an ink supply hole that they risk ink starvation. 
         [0194]    Ink supply holes  208  and  210  are both fed from a common ink supply passage  212 . The ink supply passage  212  has the capacity to supply both holes as supply hole  208  only has nozzles to its left, and supply hole  210  only has nozzles to its right. Therefore, the total flowrate through supply passage  212  is roughly equivalent to a supply passage that feeds one hole only. 
         [0195]      FIG. 25  also highlights the discrepancy between the number of channels (colors) in the ink supply—four channels—and the five channels  218  in the printhead IC  68 . The third and fourth channels  218  in the back of the printhead IC  68  are fed from the same ink supply holes  186 . These supply holes are somewhat enlarged to span two channels  218 . 
         [0196]    The reason for this is that the printhead IC  68  is fabricated for use in a wide range of printers and printhead configurations. These may have five color channels—CMYK and IR (infrared)—but other printers, such this design, may only be four channel printers, and others still may only be three channel (CC, MM and Y). In light of this, a single color channel may be fed to two of the printhead IC channels. The print engine controller (PEC) microprocessor can easily accommodate this into the print data sent to the printhead IC. Furthermore, supplying the same color to two nozzle rows in the IC provides a degree of nozzle redundancy that can used for dead nozzle compensation. 
       Pressure Pulses 
       [0197]    Sharp spikes in the ink pressure occur when the ink flowing to the printhead is stopped suddenly. This can happen at the end of a print job or a page. The Assignee&#39;s high speed, pagewidth printheads need a high flow rate of supply ink during operation. Therefore, the mass of ink in the ink line to the nozzles is relatively large and moving at an appreciable rate. 
         [0198]    Abruptly ending a print job, or simply at the end of a printed page, requires this relatively high volume of ink that is flowing relatively quickly to come to an immediate stop. However, suddenly arresting the ink momentum gives rise to a shock wave in the ink line. The LCP molding  64  (see  FIG. 19 ) is particularly stiff and provides almost no flex as the column of ink in the line is brought to rest. Without any compliance in the ink line, the shock wave can exceed the Laplace pressure (the pressure provided by the surface tension of the ink at the nozzles openings to retain ink in the nozzle chambers) and flood the front surface of the printhead IC  68 . If the nozzles flood, ink may not eject and artifacts appear in the printing. 
         [0199]    Resonant pulses in the ink occur when the nozzle firing rate matches a resonant frequency of the ink line. Again, because of the stiff structure that define the ink line, a large proportion of nozzles for one color, firing simultaneously, can create a standing wave or resonant pulse in the ink line. This can result in nozzle flooding, or conversely nozzle deprime because of the sudden pressure drop after the spike, if the Laplace pressure is exceeded. 
         [0200]    To address this, the LCP molding  64  incorporates a pulse damper to remove pressure spikes from the ink line. The damper may be an enclosed volume of gas that can be compressed by the ink. Alternatively, the damper may be a compliant section of the ink line that can elastically flex and absorb pressure pulses. 
         [0201]    To minimize design complexity and retain a compact form, the invention uses compressible volumes of gas to damp pressure pulses. Damping pressure pulses using gas compression can be achieved with small volumes of gas. This preserves a compact design while avoiding any nozzle flooding from transient spikes in the ink pressure. 
         [0202]    As shown in  FIGS. 24 and 26 , the pulse damper is not a single volume of gas for compression by pulses in the ink. Rather the damper is an array of cavities  200  distributed along the length of the LCP molding  64 . A pressure pulse moving through an elongate printhead, such as a pagewidth printhead, can be damped at any point in the ink flow line. However, the pulse will cause nozzle flooding as it passes the nozzles in the printhead integrated circuit, regardless of whether it is subsequently dissipated at the damper. By incorporating a number of pulse dampers into the ink supply conduits immediately next to the nozzle array, any pressure spikes are damped at the site where they would otherwise cause detrimental flooding. 
         [0203]    It can be seen in  FIG. 26 , that the air damping cavities  200  are arranged in four rows. Each row of cavities sits directly above the LCP main channels  184  in the LCP channel molding  176 . Any pressure pulses in the ink in the main channels  184  act directly on the air in the cavities  200  and quickly dissipate. 
       Printhead Priming 
       [0204]    Priming the cartridge will now be described with particular reference to the LCP channel molding  176  shown in  FIG. 27 . The LCP channel molding  176  is primed with ink by suction applied to the main channel outlets  232  from the pump of the fluidic system (see  FIG. 6 ). The main channels  184  are filled with ink and then the ink supply passages  182  and printhead ICs  68  self prime by capillary action. 
         [0205]    The main channels  184  are relatively long and thin. Furthermore the air cavities  200  must remain unprimed if they are to damp pressure pulses in the ink. This can be problematic for the priming process which can easily fill cavities  200  by capillary action or the main channel  184  can fail to fully prime because of trapped air. To ensure that the LCP channel molding  176  fully primes, the main channels  184  have a weir  228  at the downstream end prior to the outlet  232 . To ensure that the air cavities  200  in the LCP molding  64  do not prime, they have openings with upstream edges shaped to direct the ink meniscus from traveling up the wall of the cavity. 
         [0206]    These aspects of the cartridge are best described with reference  FIGS. 28A ,  28 B and  29 A to  29 C. These figures schematically illustrate the priming process.  FIGS. 28A and 28B  show the problems that can occur if there is no weir in the main channels, whereas  FIGS. 29A to 29C  show the function of the weir  228 . 
         [0207]      FIGS. 28A and 28B  are schematic section views through one of the main channels  184  of the LCP channel molding  176  and the line of air cavities  200  in the roof of the channel. Ink  238  is drawn through the inlet  230  and flows along the floor of the main channel  184 . It is important to note that the advancing meniscus has a steeper contact angle with the floor of the channel  184 . This gives the leading portion of the ink flow  238  a slightly bulbous shape. When the ink reaches the end of the channel  184 , the ink level rises and the bulbous front contacts the top of the channel before the rest of the ink flow. As shown in  FIG. 28B , the channel  184  has failed to fully prime, and the air is now trapped. This air pocket will remain and interfere with the operation of the printhead. The ink damping characteristics are altered and the air can be an ink obstruction. 
         [0208]    In  FIG. 29A to 29C , the channel  184  has a weir  228  at the downstream end. As shown in  FIG. 29A , the ink flow  238  pools behind the weir  228  and rises toward the top of the channel. The weir  228  has a sharp edge  240  at the top to act as a meniscus anchor point. The advancing meniscus pins to this anchor  240  so that the ink does not simply flow over the weir  228  as soon as the ink level is above the top edge. 
         [0209]    As shown in  FIG. 29B , the bulging meniscus makes the ink rise until it has filled the channel  184  to the top. With the ink sealing the cavities  200  into separate air pockets, the bulging ink meniscus at the weir  228  breaks from the sharp top edge  240  and fills the end of the channel  184  and the ink outlet  232  (see  FIG. 29C ). The sharp to edge  240  is precisely positioned so that the ink meniscus will bulge until the ink fills to the top of the channel  184 , but does not allow the ink to bulge so much that it contacts part of the end air cavity  242 . If the meniscus touches and pins to the interior of the end air cavity  242 , it may prime with ink. Accordingly, the height of the weir and its position under the cavity is closely controlled. The curved downstream surface of the weir  228  ensures that there are no further anchor points that might allow the ink meniscus to bridge the gap to the cavity  242 . 
         [0210]    Another mechanism that the LCP uses to keep the cavities  200  unprimed is the shape of the upstream and downstream edges of the cavity openings. As shown in  FIGS. 28A ,  28 B and  29 A to  29 C, all the upstream edges have a curved transition face  234  while the downstream edges  236  are sharp. An ink meniscus progressing along the roof of the channel  184  can pin to a sharp upstream edge and subsequently move upwards into the cavity by capillary action. A transition surface, and in particular a curved transition surface  234  at the upstream edge removes the strong anchor point that a sharp edge provides. 
         [0211]    Similarly, the Applicant&#39;s work has found that a sharp downstream edge  236  will promote depriming if the cavity  200  has inadvertently filled with some ink. If the printer is bumped, jarred or tilted, or if the fluidic system has had to reverse flow for any reason, the cavities  200  may fully of partially prime. When the ink flows in its normal direction again, a sharp downstream edge  236  helps to draw the meniscus back to the natural anchor point (i.e. the sharp corner). In this way, management of the ink meniscus movement through the LCP channel molding  176  is a mechanism for correctly priming the cartridge. 
         [0212]    The invention has been described here by way of example only. Skilled workers in this field will recognize many variations and modification which do not depart from the spirit and scope of the broad inventive concept. Accordingly, the embodiments described and shown in the accompanying figures are to be considered strictly illustrative and in no way restrictive on the invention.