Abstract: A discrete ink level sensing system according to the present invention includes a level sensing probe (130) with at least first and second level sensing pads (178, 180) that is placed in an ink reservoir (28). The level sensing system uses electrical conductivity of the ink to detect when the upper surface level of the ink is lower than the lowest points of the level sensing pads. The upper and lower level sensing pads are electrically connected by a sense resistor (182). A voltage sensor (174) detects across the sense resistor a voltage that depends on the ink conductivity and the position of an upper surface level of the ink with respect to the lowest points of the first and second level pads. The value of the voltage is sent to a CPU (154) that signals a user that a predetermined amount of ink should be added to the reservoir.

Abstract: A FRU assembly (10) comprises a melt chamber (20) including multiple subchambers (30) in which sticks of phase change ink (38, 40) are inserted and melted. Melted ink flows through apertures (54) to a reservoir (28) comprising multiple compartments (56). Each compartment contains a channel (90) and a siphon plate (114) that allow a siphon action that siphons melted ink in the compartments to an orifice (100) that leads to an ink jet print head (16). Heaters (52, 82, and 142) under the control of a CPU (154) melt the ink and keep the melted ink at a desired temperature during various modes of operation.

Abstract: An ink jet print head cleaning and maintenance system has a purge chamber for applying a vacuum to a nozzle orifice surface. A specialized baffle diverts ink entering the purge chamber away a vent port through which the vacuum is drawn. An elongated wipe engages and wipes the orifice surface and is preferably moved at an extremely slow rate across the surface to enhance the wiping operation. An air knife directs a narrow stream of air across a portion of the nozzle orifice surface with air from the air stream being scanned across the surface for cleaning purposes. A specialized drip edge is positioned beneath the orifice surface for directing drops of ink away from the ink jet print head, the drops of ink being generated during the cleaning procedures. A mechanically simple cam mechanism coupled to a rotatable drum of the printer may be used to shift the maintenance system against the nozzle orifice surface for cleaning purposes.

Abstract: An ink jet print head face cleaner provides a controlled air passageway through an enclosure formed against the print face. Air is directed through an inlet into a cavity in a body. The body has a face with an opening into the cavity. This face is sealingly placeable against the print face. The cavity has a limited size so that air is directed without interruption through the cavity past the ink jet apertures, and out an outlet. The cleaner body is coupled resiliently to a platform to allow positioning of the body and print faces flush with each other. A vacuum source is preferably attached to the outlet to create a subatmospheric pressure in the cavity to further seal the two faces together. A collection chamber and removable drawer are positioned below the outlet to facilitate disposing of removed ink.

Abstract: A first surface of a first metal component of an ink jet print head is bonded to a second surface of a second metal component of the ink jet print head, the first and second surfaces being of materials having the same or similar coefficients of thermal expansion. A layer of filler material is electroplated or otherwise placed on at least one of these surfaces. The filler material has a melting point which is below the melting point of the first and second components, and the total thickness of the filler material on the surfaces together is in the range of from approximately one-sixteenth micron to approximately five microns, with one-eighth micron to two microns being a preferred range. These surfaces are placed together and subjected to heat and pressure to diffusion bond the surfaces without melting the filler material. The diffusion bonding is performed in one approach until no more than approximately one micron of filler material remains between the surfaces.

Abstract: An ink jet head 10 has an ink chamber 14 which receives ink from an ink inlet passageway 38. Pressure pulses applied to the ink chamber cause the ejection of ink drops from an ink drop forming orifice 23 and toward printing medium. A purging outlet 41 communicates with the ink chamber through a purging passageway 40. During purging, ink flows in a vortical path through the ink chamber 14 from the ink inlet passageway 38 to the purging outlet passageway 40. This sweeps air bubbles and contaminants from the ink chamber walls and removes them from the ink chamber. Ink pressure within the ink chamber 14 may be elevated to increase the flow of ink during purging. Also, a negative pressure may be applied to the purging outlet during purging. Variable frequency pressure pulses may also be applied to the ink chamber to assist the purging process.