Abstract: An ink jet printer includes a movable carriage supported above an ink-receiving medium by a rail defining a carriage axis, with a cartridge holder mounted on said carriage having a plurality of cartridge compartments each receiving a respective thermal ink jet printer cartridge. Each cartridge is provided with three datum surfaces located on the perimeter of a sidewall of the cartridge, and sufficiently spaced apart from each other and from the center of gravity of the cartridge to provide accurate and stable alignment. More particularly, the nozzle plate of the cartridge is attached to a lower surface of snout portion such that the Y axis of the nozzle plate is substantially parallel to the first sidewall, with the first and second datum surfaces at the front and rear of a lower end of the ink reservoir portion straddling the snout and the third datum surface at an upper end of the ink reservoir portion.

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 sorer, more ductile plastic material than the rigid 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 interior frame structure is fabricated from a polymer blend composition comprising (A) at least one polymer selected from the group consisting of a polyethylene and a copolymer of ethylene and an alpha-olefin and (B) at least one polymer selected from the group consisting of a polypropylene and a copolymer of propylene and ethylene, wherein (A) is different from (B).

Abstract: A method of attaching a flexible interconnection circuit assembly to 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. An ink reservoir is connected through a standpipe defined by the rigid frame material with the headland region. The second plastic material coats the headland region, and portions of flap and tab sides of the snout regions. The interconnection circuit assembly includes a thermoplastic cover layer, a flexible tab circuit and a printhead die and orifice plate affixed to the tab circuit.

Abstract: Precise alignment between two or more nozzle plates affixed to print cartridges installed in a single carriage of an ink printer is achieved by machining datum projections on each print cartridge after its nozzle plate has been permanently secured to the print cartridge. The machined datum projections on the print cartridge contact surfaces on the carriage when the print cartridge is installed in the carriage such that the dimensions of the datums affect the position of the cartridge, and hence the nozzle plate, within the carriage.

Abstract: A thermal ink-jet (TIJ) pen including a plastic frame structure and side covers. To attach the covers to the plastic frame without the use of adhesives, screws, thermal or ultrasonic processes, protruding metal tabs from the cover are press fit into corresponding recess features of the plastic frame. The tabs are designed to displace plastic surrounding the frame recesses to lock the cover to the frame. The resulting frame/cover seam resists shear, axial and transverse forces that occur as a result of externally applied loads to the pen.

Abstract: A thermal ink-jet pen cartridge including an ink reservoir for maintaining ink under negative pressure. The ink reservoir is coupled to the printhead via a discharge port. To prevent air bubbles from entering the reservoir via the discharge port and printhead after ink is expelled via the thermal process, a check valve is placed in the fluid path between the ink reservoir and the printhead at the discharge port. The check valve is a mesh having a very small mesh opening sufficient to prevent air bubbles from passing through under normal pressures. The check valve also serves the function of a particulate filter to prevent contamination of the printhead by particles from the ink reservoir.

Abstract: A collapsible ink reservoir structure to facilitate assembly of a replaceable or refillable printer ink cartridge is comprised of a relatively rigid inner frame and flexible membranes 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 reservoir structure is a separate unit from the ink discharge aperture device which is assembled and mounted in an outer housing and includes the inner frame and ink bags formed of films to form the cartridge assembly. Multiple reservoirs can be formed within the structure to permit the use of different colorants in each reservoir. The structure preferably contains an ink pressure regulator within each reservoir to maintain a negative pressure therein.

Abstract: A method of encapsulating exposed conductive traces connecting an ink-jet printhead die to an interconnection circuit attached to a 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. The headland region is defined at the tip of a snout region of the cartridge. The second plastic material coats the headland region. The printhead assembly includes a thermoplastic cover layer, a flexible interconnection circuit and a printhead die and orifice plate affixed to the circuit. The second plastic material at the headland region includes regions of additional material. The printhead assembly is attached to the headland region. Heat and pressure are applied to melt the regions of additional second plastic material so that this material reflows to encapsulate the die traces.

Abstract: In one embodiment, a metal restraining element is used to reduce thermal expansion/contraction stress between a nozzle member and a print cartridge body. In a preferred embodiment, a nozzle member containing an array of orifices has a substrate, having heater elements formed thereon, affixed to a back surface of the nozzle member. The back surface of the nozzle member extends beyond the outer edges of the substrate. Ink is supplied from an ink reservoir within a print cartridge body to the orifices by a fluid channel within a barrier layer between the nozzle member and the substrate. The nozzle member is adhesively sealed with respect to the print cartridge body by forming an ink seal circumscribing the substrate, between the back surface of the nozzle member and the body.

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 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 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 linear thruster (10) comprises a thruster assembly (15) and a compliant head assembly (100). Thruster assembly (15) includes a housing (20), a pair of guide rods (30) supported by bearings (29) in housing (20), a thrust plate (40) attached below housing (20) to guide rods 30, a power unit, such as pneumatic cylinder (50), and a thrust rod (60). Compliant head assembly (100) includes a translation block (120), a set of first leaf springs (140) supporting translation block (120) above thrust plate (40) such that translation block (120) can move forward and rearward, a compliant head (160), and a set of second leaf springs (180) supporting compliant head (160) from translation block (120) at a position below thrust plate (40) such that compliant head (160) can move left and right due to resiliency of second leaf springs (180) and forward and rearward with movement of translation block (120).

Abstract: A rigid external case structure for a thermal ink-jet pen cartridge, which includes an ink reservoir within the case. The case includes an external frame structure made of an engineering plastic, and defining an open loop, with opposed open areas defined on each opposed side of the loop. Two opposed thin metal side cover plates are attached to the frame structure to cover the open areas, and provide rigidity to the case structure. As a result, the frame structure is substantially non-compressible in response to forces applied against the side members or against the frame, protecting the ink reservoir and preventing ink drool from the pen printhead.

Abstract: A method of assembling a collapsible ink reservoir for a liquid ink printer cartridge comprising the steps of attaching a first sidewall to a frame member along a sealable junction to form an open assembly; assembling a pressure regulator; inserting the pressure regulator of said assembly step into the open assembly of said attaching step; and affixing a second sidewall to the open assembly of said attaching step to form an enclosed assembly.

Abstract: Precise alignment between two or more nozzle plates affixed to print cartridges installed in a single carriage of an ink printer is achieved by machining datum projections on each print cartridge after its nozzle plate has been permanently secured to the print cartridge. The machined datum projections on the print cartridge contact surfaces on the carriage when the print cartridge is installed in the carriage such that the dimensions of the datums affect the position of the cartridge, and hence the nozzle plate, within the carriage.

Abstract: A heated film die for the fabrication of plastic containers such as bags, envelopes, balloons, bladders, etc.. The die is an integrated sectionalized structure having independent, adjacent, electrically heated, temperature regulated, die sections which are maintained at different temperatures, for performing, simultaneously, two or more of operations such as, cutting, staking and forming, in plastic container fabrication. A lower temperature heat sink between adjacent die sections provides thermal isolation between the die sections.