Abstract: An ink-jet swath printer employing a cartridge with a spring bag primary reservoir and an auxiliary ink reservoir interconnected via a tube to form a closed ink replenishment system. The primary reservoir creates a negative pressure which draws ink from the auxiliary reservoir as ink is expelled from the cartridge printhead during printing operations. The auxiliary reservoir can either be mounted on the cartridge carriage or on the printer body. The auxiliary reservoir is a large capacity collapsible bag mounted below the level of the printhead to establish an ink pressure head at the primary reservoir connection which is not so large as to destroy or diminish the negative pressure and allow ink to drool from the printhead, yet is sufficient to permit replenishment of the primary reservoir to avoid printhead ink starvation.

Abstract: A pressure head (10) for contacting pressure areas through relative movement in the vertical Z-direction includes a frame (20), a pair of horn assemblies (12) each including a horn (100) for contacting a workpiece (230), the horn (100) supported by a gimbal (40) connected to the frame (20) and a pair of pressure assemblies 15, each including a pressure cylinder (310) for applying a force to its horn (100). The gimbal (40) has only a single outer torsion member (50) and supports the horn (100) such that the horn (100) can rotate about orthogonal X and Y rotation axes and can translate in the Z-direction relative to frame (20). Each gimbal (40) having only a single outer torsion member (50) allows a pair of gimbals (40) to support horns (100) in close proximity for operation on two proximal work areas.

Abstract: A method for joining two materials together to form a compact leak-resistant seal, particularly suited for use in thermal inkjet print cartridge ink reservoirs. The seal employs a shrink fit to clamp the two materials together. The method includes the steps of forming the first material into a desired first shot structure, placing the first shot structure in a second shot mold, and injecting the second material into the mold under adequate pressure and at an appropriate temperature. The second material has a high degree of mold shrinkage. Upon cooling, the second material shrinks tightly onto the first shot structure to form a molded joint which keeps air out and ink in when wetted and during normal shipping, storage, and operating conditions.

Abstract: A method of attaching an ink-jet printhead assembly to the headland region of an ink-jet pen cartridge to form a leak-proof seal without the use of any externally applied adhesive material. The cartridge includes a frame structure fabricated of a rigid plastic frame member formed of a first plastic material and a polymeric second material molded to the frame member. A headland region is defined at the tip of a snout region of the cartridge. An ink reservoir is connected through a standpipe defined by the rigid frame material with the headland region. The second plastic material defines a printhead assembly support structure which circumscribes a printhead and the stand-pipe. The printhead assembly is attached to the support structure after alignment by heatstaking the printhead assembly to the second plastic material defining the support structure.

Abstract: A method of attaching an ink-jet printhead assembly to the headland region of an ink-jet pen cartridge. The cartridge includes a frame structure fabricated of a rigid plastic frame member formed of a first plastic material and a polymeric second material molded to the frame member. A headland region is defined at the tip of a snout region of the cartridge. The second plastic material forms a compliant beam at the headland region. The printhead assembly includes a dielectric layer and a printhead die. The printhead assembly is attached to the headland region after alignment by attaching the dielectric layer of the assembly to the compliant beam formed by the second plastic material. As the pen is subjected to temperature extremes, and the first plastic material expands or shrinks more than the cover layer and flexible interconnection circuit materials, the compliant beam flexes, reducing stresses which can lead to pen failures.

Abstract: A method for ink-jet printing including providing a collapsible ink reservoir structure to facilitate assembly of a replaceable or refillable printer ink cartridge, the cartridge being formed of a relatively rigid frame (20) and flexible membranes (22, 24) forming an ink reservoir having side walls which collapse to a substantially flat shape to minimize the amount of ink remaining in the reservoir structure after computer generated printing has depleted the ink from the cartridge. The ink reservoir structure is a separate unit which is assembled and mounted in an outer housing (10) to form an ink cartridge and preferably contains an ink pressure regulator (30) which maintains a negative pressure therein.

Abstract: An ink-jet pen cartridge having a frame structure fabricated of a rigid plastic frame member formed of a first plastic material and an elastomeric second material. The cartridge includes an ink reservoir and an ink-jet printhead mounted to a headland region defined at the tip of a snout region of the cartridge. The ink reservoir is connected through a standpipe defined by the rigid frame material with the printhead. The second plastic material coats the inner surface of the standpipe and the headland region, to eliminate a joint at which the first and second plastic material meet in the ink path between the ink reservoir and the printhead. This eliminates a leak risk at such a joint.

Abstract: A method for filling an ink reservoir of an ink-jet cartridge. A cartridge is provided which includes a frame structure having an external frame structural member fabricated from a first rigid plastic material and an inner frame member fabricated from a second plastic material, the inner member lining an interior surface of the external frame member. The cartridge has first and second impervious membranes joined to the inner frame member to form, with the inner frame member, an ink reservoir for holding a supply of ink, and an ink fill port comprising a passage-way defined through the external frame member, the passage-way lined with said second material of said inner member and communicating with the interior of the reservoir. Ink is released into the reservoir from an ink supply through the fill port, which is then sealed.

Abstract: A thin pen cartridge for a thermal ink-jet (TIJ) printer, to be carried in a pen carriage along a carriage scan axis above the print medium. The pen height and depth are at least twice the pen width measured along the scan axis in order to achieve a high volume pen. The reduction in pen width permits the carriage width along the scan axis to be reduced, in turn reducing the footprint size of the TIJ printer.

Abstract: A collapsible ink reservoir structure (25) to facilitate assembly of a replaceable or refillable printer ink cartridge is comprised of a relatively rigid frame (20) and flexible membranes (22, 24) forming an ink reservoir having side walls which collapse to a substantially flat shape to minimize the amount of ink remaining in the reservoir structure after computer generated printing has depleted the ink from the cartridge. The structure (25) is a separate unit which is assembled and mounted in an outer housing (10) to form an ink cartridge. The structure preferably contains an ink pressure regulator (30) which maintains a negative pressure therein.

Abstract: An inkjet printhead is mounted on a cartridge which has an outer casing member, an inner collapsible reservoir formed by non-elastic flexible walls, and an internal spring means inside the reservoir for creating negative pressure in the collapsible reservoir during the filling and storage of ink in the collapsible reservoir as well as during the dispensing of ink from the collapsible reservoir to the printhead.

Abstract: A system for monitoring ink volume in an ink reservoir carried on-board the print head carriage and replenishing the ink as needed to maintain an adequate volume of ink in the print head carriage ink reservoir, such replenishment coming from an off-board ink supply not positioned on the print head carriage.

Abstract: In a computer-driven ink-jet printer, a carriage-borne ink reservoir system adjacent a print head, having a housing and a movable wall within and in sealing contact with the housing, the movable wall being observable and forming a portion of a variable volume ink chamber within the housing, the position of the movable wall being related to the volume of ink contained in the carriage-borne ink reservoir.

Abstract: A method of attaching an ink-jet printhead assembly to the headland region of an ink-jet pen cartridge to form a leak-proof seal without the use of any externally applied adhesive material. The cartridge includes a frame structure fabricated of a rigid plastic frame member formed of a first plastic material and a polymeric second material molded to the frame member. A headland region is defined at the tip of a snout region of the cartridge. An ink reservoir is connected through a standpipe defined by the rigid frame material with the headland region. The second plastic material defines a printhead assembly support structure which circumscribes a printhead and the standpipe. The printhead assembly is attached to the support structure after alignment by heatstaking the printhead assembly to the second plastic material defining the support structure.

Abstract: An ink-jet print cartridge is formed by a rigid outer protective case and an inner ink reservoir having a flexible wall portion and a rigid wall portion which together form a sealed compartment. The flexible wall portion includes two opposing membranes sealed at their periphery to an inner loop-like frame which is integrated with a portion of the outer case. The outer protective case also covers a snout having a shortened length in the media advance direction to allow media positioning rollers closely adjacent to the print zone. The snout includes internal filters in an ink passageway from the reservoir to print nozzles at the end of the snout.

Abstract: A closed ink replenishment system for replenishing the supply of ink in negative pressure spring-bag reservoirs in a printer/plotter. A tube runs between each cartridge reservoir and an auxiliary reservoir mounted to the printer/plotter frame to form the closed ink system. As ink is depleted from the spring-bag reservoir during printing operation, the negative pressure in the cartridge increases, drawing ink through the tube from the auxiliary reservoir into the cartridge until the negative pressure decreases to an equilibrium point. As a result, the volume of ink within the spring-bag reservoir remains substantially constant so long as there is ink remaining within the auxiliary reservoir. This maintains the print quality. The auxiliary reservoir is a flat bag mounted on a spring-biased platform, which acts as a height regulating system. As ink is depleted from the auxiliary bag, the height of the platform and bag increases to maintain a constant pressure and elevation head at the spring-bag reservoir.

Abstract: A thermal ink-jet pen cartridge having a rigid external frame member fabricated of a rigid engineering plastic, and an interior frame structure attached thereto, formed of a softer, more ductile plastic material than an engineering plastic. An ink reservoir is defined by the interior structure and a pair of flexible bag membranes formed of a plastic material impervious to the ink and compatible with the interior member material, allowing the membranes to be joined to the interior member to form a leak-proof joint. The external structure has locking features formed into an interior surface. When the interior member is injection molded to the external member, the molten material flows into and around the locking features, securing the interior member to the external member and resisting the shrinkage forces as the molten material cools. The ink reservoir is filled through a fill port passageway extending through the external frame member and the inner member.

Abstract: A method for designing a second ink-jet cartridge characterized by a datum structure, an ink reservoir system and a printhead structure, given a first cartridge design, wherein the printhead structure of the two cartridges are different. The method uses a common datum structure and ink reservoir system for both the first and second cartridges, to save on development and tooling expenses. The cartridges differ in the shapes or configurations of the headland structures, the flexible interconnect circuits, the nozzle plates, the ink channels or the printhead substrates.

Abstract: A method of attaching an ink-jet printhead assembly to the headland region of an ink-jet pen cartridge. The cartridge includes a frame structure fabricated of a rigid plastic frame member formed of a first plastic material and a polymeric second material molded to the frame member. A headland region is defined at the tip of a snout region of the cartridge. The second plastic material forms a compliant beam at the headland region. The printhead assembly includes a dielectric layer and a printhead die. The printhead assembly is attached to the headland region after alignment by attaching the dielectric layer of the assembly to the compliant beam formed by the second plastic material. As the pen is subjected to temperature extremes, and the first plastic material expands or shrinks more than the cover layer and flexible interconnection circuit materials, the compliant beam flexes, reducing stresses which can lead to pen failures.

Abstract: A method for joining two materials together to form a compact leak-resistant seal, particularly suited for use in thermal inkjet print cartridge ink reservoirs. The seal employs a shrink fit to clamp the two materials together. The method includes the steps of forming the first material into a desired first shot structure, placing the first shot structure in a second shot mold, and injecting the second material into the mold under adequate pressure and at an appropriate temperature. The second material has a high degree of mold shrinkage. Upon cooling, the second material shrinks tightly onto the first shot structure to form a molded joint which keeps air out and ink in when wetted and during normal shipping, storage, and operating conditions.