WO1999044830A1 - Ink container refurbishment system - Google Patents

Abstract

Alternative methods for refurbishing a single-use ink delivery container (12) for a printing system are described. The refurbishing methods include electrical and mechanical reconfiguration or replacement of original elements on the ink delivery container. Each method utilises an existing ink fluid outlet (30), electrical connector (54) and an information storage device on the ink delivery container.

Description

INK CONTAINER REFURBISHMENT SYSTEM

This application is a continuation-in-part of U.S. Patent Application Serial

Number 09/034,719, attorney docket number 10971937-1, entitled "Ink Container

Refurbishment Method" filed March 4, 1998 which is a continuation-in-part of U.S.

Patent Application Serial Number 08/785,580, attorney docket number 10960726-1,

entitled "Apparatus Controlled by Data From Consumable Parts With Incorporated

Memory Devices" filed January 21, 1997. This application is also a continuation-in-

part of U.S. Patent Application Serial Number 09/053,556, attorney docket number

10980815-1, entitled "Replaceable Ink Container with Fluid Interconnect for Coupling

to an Ink-jet Printer" filed April 1, 1998 which is a continuation-in-part of U.S. Patent

Application Serial Number 08/566,821 , attorney docket 10951185- 1 , entitled "Self-

Sealing Fluid Interconnect with Double Sealing Septum ", filed December 4, 1995. In

addition, this application is related to commonly assigned U.S Patent Application Serial

Number 09/034,874 filed March 4, 1998, attorney docket number 10971933-1, entitled

"Ink Delivery System Adapter ", U.S. Patent Application Serial Number 09/034,875

filed March 4, 1998, attorney docket number 10971934- 1 , entitled "Electrical

Refurbishment for Ink Delivery System ", and to U.S. Patent Application Serial Number attorney docket number 10971935-1, entitled "Large Capacity Ink

Delivery System Adapter " filed herewith.

TECHNICAL FIELD

This invention relates in general to ink-jet printing systems, and in particular to

refurbishing ink containers for ink-jet printing systems.

BACKGROUND ART

One type of prior art ink-jet printer has a printhead mounted to a carriage which

is moved back and forth over print media, such as paper. As the printhead passes over

appropriate locations on the print media, a control system activates the printhead to eject

ink drops onto the print media and form desired images and characters. To work

properly, such printers should have a reliable supply of ink for the printhead.

One category of ink-jet printer uses an ink supply that is mounted to and moves

with the carriage. In some types, the ink supply is replaceable separately from the

printhead. In others, the printhead and ink supply together form an integral unit that is

replaced as a unit once the ink in the ink supply is depleted.

Another category of printer, referred to as an "off-axis" printing system, uses ink

supplies which are not located on the carriage. One type replenishes the printhead

intermittently. The printhead will travel to a stationary reservoir periodically for

replenishment. U.S. Patent Application Serial Number 09/034,719 describes another printing system wherein the printhead is fluidically coupled to a replaceable ink supply

or container via a conduit such as a flexible tube. This allows the printhead to be

continuously replenished during a printing operation.

In the parent application to this application, a replaceable off-axis ink container

is described which has a memory device mounted to the housing. When inserted into

the printer station, an electrical connection between the printer and the memory device

is established. This electrical connection allows for the exchange of information

between the printer and the memory. The memory device stores information which is

utilized by the printer to ensure high print quality. This information is provided to the

printer automatically when the cartridge is mounted to the printer. The exchange of

information assures compatibility of the cartridge with the printer.

The stored information further prevents the use of the container after it is

depleted of ink. Operating a printer when the reservoir has been depleted of ink may

damage or destroy the printhead. The memory devices concerned with this application

are updated with data from the printhead concerning the amount of ink left in the

reservoir as it is being used. When a new cartridge is installed, the printer will read

information from the memory device that is indicative of the reservoir volume. During

usage, the printing system estimates ink usage and updates the memory device to

indicate remaining ink in the cartridge. Once the ink in the ink container is substantially

depleted, the memory device is updated to reflect an out-of-ink condition. The depleted

of ink cartridges and memory devices are then discarded. DISCLOSURE OF THE INVENTION

The present invention comprises alternative methods for refurbishing a single-

use ink delivery container for a printing system. The refurbishing methods include

electrical and mechanical reconfiguration or replacement of original elements on the ink

delivery container. Each method utilizes an existing ink fluid outlet, electrical

connector and an information storage device on the ink delivery container.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic drawing of a printing system having an original

equipment ink delivery system.

Figure 2 is an isometric view of a printer incorporating the printing system as

described with respect to Figure 1.

Figure 3 is an end isometric view of an ink container of the printing system of

Figure 1.

Figure 4 is a side view of the ink container of Figure 3.

Figure 5 is a partial enlarged proximal end view of the ink container of Figure 3.

Figure 6 is a sectional side view of the ink container of Figure 3 taken along the

line 6-6 of Figure 5.

Figure 7 is a partial enlarged isometric view of a portion of the printer of Figure

2, showing the ink container receptacles. Figure 8 is an enlarged partial isometric and sectional view of the printer of

Figure 2 taken along the line 8-8 of Figure 7.

Figure 9 is an enlarged isometric view of an interface portion of the printer of

Figure 2.

Figure 10A is a partial sectional view of the interface portion of the printer

which is shown in Figure 9 taken along the line 10A-10A of Figure 9 and showing also

a partial sectional view of the ink container installed.

Figure 1 OB is an enlarged view of the printer of Figure 10 A, taken along the line

10B-10B of Figure ION Figure 11 A is a partially exploded isometric view of the ink container of Figures

10A, 10B, as shown from the distal end.

Figure 1 IB is a partially exploded isometric view of the ink container of Figures

10 A, 10B, as shown from the proximal end.

Figure 12 is a further exploded isometric view of the ink container of Figures

ION 10B.

Figure 13 is an enlarged side view showing the inductive fluid level sensors for

the ink container of Figures 10 A, 10B, shown detached from the ink container.

Figure 14 is a flow chart depicting the process for refurbishing ink container 12.

Figure 15 is a sectional view of the ink container of Figs. 10A and 10B, with the

leading cap removed. Figure 16 is a sectional view of the ink container of Figures 10A, 10B, with the

leading cap removed and showing the ink container being refilled with ink.

BEST MODE FOR CARRYING OUT THE INVENTION

Although the present invention comprises methods for refurbishing ink

containers, the invention may be more clearly understood with a thorough discussion of

the printer and original equipment ink container.

Referring to Figure 1, a printing system 10 having an ink container 12, a

printhead 14 and a source of pressurized gas, such as a compressor 16, is shown.

Compressor 16 is connected to ink container 12 with a conduit 18. A marking fluid 19

such as ink is provided by ink container 12 to printhead 14 by a conduit 20. Ink

container 12 includes a fluid reservoir 22 for containing ink 19, an outer shell 24, and a

chassis 26. In the preferred embodiment, chassis 26 includes air inlet 28 configured for

connection to conduit 18 for pressurizing the outer shell 24 with air. A fluid outlet 30 is

also included in the chassis 26. The fluid outlet 30 is configured for connection to the

conduit 20 for providing a connection between the fluid reservoir 22 and fluid conduit

20.

In the preferred embodiment, the fluid reservoir 22 is formed from a flexible

material such that pressurization of outer shell 24 produces a pressurized flow of ink

from the fluid reservoir 22 through the conduit 20 to the printhead 14. The use of a

pressurized source of ink in the fluid reservoir 22 allows for a relatively high fluid flow rate from the fluid reservoir 22 to the printhead 14. The use of high flow rates or high

rates of ink delivery to the printhead make it possible for high throughput printing by

the printing system 10.

The ink container 12 also includes a plurality of electrical contacts, as will be

discussed in more detail subsequently. The electrical contacts provide electrical

connection between circuitry on ink container 12 and printer control electronics 32. The

printhead control electronics 32 control various printing system 10 functions such as,

but not limited to, printhead 14 activation to dispense ink and activate pump 16 to

pressurize the ink container 12. Ink container 12 includes an information storage

device 34 and ink volume sensing circuitry 36. The information storage device 34

provides information to the printer control electronics 32 such as ink container 12

volume as well as ink characteristics. The ink volume sensing circuitry 36 provides

signals relating to current ink volume in ink container 12 to the printer control

electronics 32.

Figure 2 depicts one embodiment of printing system 10 shown in perspective.

Printing system 10 includes a printing frame 38 constructed for containing several ink

containers 12 simultaneously. The embodiment shown in Figure 2 has four similar ink

containers 12. In this embodiment, each ink container contains a different ink color so

that four color printing can be accomplished using cyan, yellow, magenta and black

inks. Printer frame 38 has a control panel 40 for controlling operation of printer 10 and

a media slot 42 from which paper is ejected. Referring also, to Figure 1, as ink 19 in each ink container 12 is exhausted,

container 12 is replaced with a new ink container 12 containing a new supply of ink. In

addition, ink containers 12 may be removed from the printer frame 38 for reasons other

than an out of ink condition such as changing inks for an application requiring different

ink properties or for use on different media. It is important that the replacement ink

container 12 form reliable electrical connection with corresponding electrical contacts

associated with the printer frame 38 as well as properly form necessary interconnects so

that printing system 10 performs reliably.

Figures 3 and 4 depict an original equipment ink container 12 having an outer

shell 24 which contains the fluid reservoir 22 (Fig. 1) for containing ink 19. Outer shell

24 has a leading cap 50 secured on a leading end and a trailing cap 52 on secured on a

trailing end, relative to a direction of insertion for the ink container 12 into the printer

frame 38. Leading cap 50 has an aperture 44 on its leading end through which air inlet

28 and fluid outlet 30 from reservoir 22 (Fig. 1) protrudes. Reservoir chassis 26 has an

end or base which abuts leading cap 50 so that air inlet 28 and ink outlet 30 protrude

through aperture 44. Aperture 44 is surrounded by a wall 45, placing aperture 44 within

a recess. Air inlet 28 and fluid outlet 30 are configured for connection to compressor 16

and printhead 14, respectively, (Fig. 1) once ink container 12 is properly inserted into

the printer frame 38. Air inlet 28 and fluid outlet 30 will be discussed in more detail

subsequently. Leading cap 50 also has another aperture 46 which is located within the recess

surrounded by wall 45. The base or end of chassis 26 is also exposed to aperture 46. A

plurality of flat electrical contact pads 54 are disposed on reservoir chassis 26 and

positioned within aperture 46 for providing electrical connection between circuitry

associated with the ink container 12 and printer control electronics 32. Contact pads 54

are rectangular and arranged in a straight row. Four of the contact pads 54 are

electrically connected to information storage device 34 and four are electrically

interconnected to ink volume sensing circuitry 36 described with respect to Figure 1. In

a prefeπed embodiment, information storage device 34 is a semiconductor memory and

the ink volume sensing circuitry 36 comprises an inductive sensing device. Wall 45

helps protect information storage device 34 and contact pads 54 from mechanical

damage. In addition, wall 45 helps minimize inadvertent finger contact with contact

pads 54. Contact pads 54 will be discussed in more detail with respect to Figure 5.

In a prefeπed embodiment, ink container 12 includes one or more keying and

guiding features 58 and 60 disposed on opposite sides of leading cap 50 of container 12.

Keying and guiding features 58 and 60 protrude outward from sides of container 12 to

work in conjunction with coπesponding keying and guiding features or slots on the

printer frame 38 (Fig. 2) to assist in aligning and guiding the ink container 12 during

insertion of the ink container 12 into the printer frame 38. Keying and guiding features

58 and 60 also provide a keying function to insure that ink containers 12 having proper ink parameters, such as proper color and ink type, when inserted into a given slot in

printer frame 38.

A latch shoulder 62 is provided on one side of trailing cap 52. Latch shoulder

62 works in conjunction with coπesponding latching features on the printer portion to

secure the ink container 12 within the printer frame 38 so that interconnects such as

pressurized air, fluidic and electrical are accomplished in a reliable manner. Latch

shoulder 62 is a molded tang which extends downwardly relative to a gravitational

frame of reference. Ink container 12 as shown in Figure 4 is positioned for insertion

into a printer frame 38 (Fig. 2) along the Z-axis of coordinate system 64. In this

orientation gravitational forces on the ink container 12 are along the Y-axis.

Figure 5 depicts an enlarged view of electrical contact pads 54. An upstanding

guide member 72 is mounted to chassis 26 adjacent contact pads 54. Electrical contact

pads 54 include two pairs of contact pads 78, each pair being electrically connected to

one of the volume sensing circuits 36, shown in Figure 1. The four contact pads 80

spaced between each pair of pads 78 and contact pads 80 are electrically connected to

the information storage device 34. Each pair of volume sensing contact pads 78 is

located on an outer side of the row of contact pads 54. Contact pads 78 are part of a

flexible circuit 82 (Fig. 13) which is mounted to the base 56 by fasteners 84. The four

intermediate contacts 80 located between the pairs of volume sensing contacts 78 are

metal conductive layers disposed on a nonconductive substrate 86 such as epoxy and

fiberglass. Memory device 34 is also mounted on substrate 86 and is connected by

10 conductive traces (not shown) formed in substrate 86. Memory device 34 is shown

encapsulated by a protective coating such as epoxy. A backside of substrate 86, opposite

contacts 80, is bonded by adhesive or attached to the chassis 26 by fasteners 84.

It can be seen from Figure 6 that the guide member 72 extends along a Z-axis in

coordinate system 64. Guide member 72 has a pointed, tapered distal end. Guide

member 72 provides an important guiding function to insure proper electrical

connection is accomplished during the insertion of ink container 12 into the printer

frame 38. Figure 7 depicts one ink container 12 shown secured within an ink container

receptacle or receiving slot 88 of receiving station 89 within the printer frame 38. Ink

container indicia 90 may be positioned proximate each ink container receptacle 88. The

ink container indicia 90 may be a color swatch or text indicating ink color to assist the

user in color matching for inserting the ink container 12 in the proper slot 88 within the

ink container receiving station 89. As discussed previously, the keying and guiding

features 58 and 60 shown in Figures 3 and 4 prevent ink containers 12 from being

installed in the wrong slot 88. Installation of an ink container 12 in the wrong

receptacle 88 can result in improper color mixing or the mixing of inks of different ink

types each of which can result in poor print quality.

Each receiving slot 88 within the ink container receiving station 89 includes keying and

guiding features or slots 92 and a latching portion 94. Keying and guiding slots 92

cooperate with the keying and guiding feature 60 (Fig. 3) to guide ink container 12 into

the ink container receiving station 88. The keying and guiding slot 92 coπesponding to

11 the keying and guiding feature 58 (Fig. 3) on ink container 12 is not shown. Latch

portion 94 is configured for engaging the coπesponding latch feature 62 on the ink

container 12. The geometries of keying and guiding slots 92 vary from one receptacle

88 to the other to assure compatibility between ink containers and receptacles.

Figure 8 shows a single ink container receiving slot 88 within the ink container

receiving station 89. Slot 88 includes interconnect portions for interconnecting with the

ink container 12. In the prefeπed embodiment these interconnect portions include a

fluid inlet 98, and air outlet 96 and an electrical interconnect portion 100. Each of the

interconnects 96, 98, and 100 are positioned on a floating platform 102 which is biased

by coil springs 101 (Fig. 10A) along the Z-axis toward the installed ink container 12.

Fluid inlet 98 and air outlet 96 are configured for connection with the coπesponding

fluid outlet 30 and air inlet 28 (Fig. 3), respectively on the ink container 12. The

electrical interconnect 100 is configured for engaging electrical contacts 54 on the ink

container 12.

It is the interaction between the keying and guiding features 58 and 60

associated with the ink container 12 and the coπesponding keying and guiding feature

92 associated with the ink container receiving station 89 which guide the ink container

12 during the insertion such that proper interconnection is accomplished between the

ink container 12 and the printer frame 38. In addition, sidewalls associated with each

slot 88 in the ink container receiving station 89 engage coπesponding sidewalls of the

12 ink container 12 to assist in guiding and aligning ink container 12 during insertion into

slot 88.

Figures 9 and 10A illustrate further details of the floating platform 102.

Platform 102 is spring biased by coil springs 101 in a direction opposite the direction of

insertion of the ink container 12 into the ink container receiving slot 88 (Fig. 10A).

Platform 102 is biased towards mechanical restraints (not shown) which limit the

motion of platform 102 in each of the X, Y, and Z axes. Therefore, platform 102 has a

limited degree of motion in each of the X, Y, and Z axes of coordinate system 64.

Electrical connector 100 is supported by and protrudes from platform 102.

Electrical connector 100 is generally rectangular, having two lateral sides 107, upper

and lower sides, and a distal end 105. A plurality of resilient, spring-biased electrical

contacts 104 protrude from end 105. Electrical contacts 104 are thin wire-like

members which engage coπesponding electrical contacts 54 (Fig. 3) associated with ink

container 12 to electrically connect ink container 12 with the printer controller 32 (Fig.

1). Electrical connector 100 has a guide slot 106 on its upper side. Guide slot 106 has

opposed converging walls which cooperate to engage guide member 72 (Figs. 5 and

10B). Guide member 72 engages guide slot 106 to properly align contacts 104 with

contact pads 54. Figure 10B shows contact pads 54 properly aligned with electrical

contacts 104.

Referring to Figures 9 and 10A, fluid inlet 98 and air outlet 96 protrude from

floating platform 102. Fluid inlet 98 includes an ink supply sleeve 110 suπounding a

13 conduit 108. Needle 108 has a port near its distal end. A collar 111 sealingly and

slidingly engages needle 108. A spring 113 urges collar 111 toward the distal end,

blocking the port.

Referring still to Figure 10 A, ink outlet 30 is a cylindrical member having a

septum 122 on its distal end. Septum 122 has a slit for receiving needle 108. In a

prefeπed embodiment, a check valve comprising a ball 124 and spring 126 are located

in ink outlet 30 to prevent outflow of ink until needle 108 is inserted. Ball 124 seats

against septum 122 and is pushed away from septum 122 by needle 108. Air inlet 28 is

also a cylindrical member having a septum 128 with a slit.

As shown in Figures 11 A, 1 IB and 14, shell 24 is a generally rectangular

member with a cylindrical neck 130 on its leading end. Chassis 26 is a circular disk or

plug which inserts and seals in neck 130 with the leading side of chassis 26 flush with

the rim of neck 130. Reservoir 22 is a collapsible reservoir such as a collapsible bag

which fits within shell 24. An opening in reservoir 22 is sealingly joined to chassis 26.

Chassis 26 along with shell 24 and caps 50, 52 define a housing for reservoir 22. Shell

24 is airtight, creating a pressure chamber 132 in the space surrounding reservoir 22.

Air inlet 30 communicates with pressure chamber 132. Refeπing to Figure 12, rigid

stiffener plates 134 are attached to opposite outer sides of reservoir 22. Outer shell 24

of ink container 12 is sealed to flexible reservoir 22 and, thus, acts as a pressure vessel.

During usage, the pressurization of outer shell 24 allows pressurization of collapsible

reservoir 22.

14 The two inductive ink volume sensor coils 36 are formed on opposite legs of

flexible circuit 82. Each of the coils 36 has two leads 138 (Fig. 13) connected to one of

the pairs of sensor contacts 78 (Fig. 3). One of the coils 36 locates on one side of

reservoir 22 while the other is on the opposite side. When connected to printing system

10, controller 32 (Fig. 1) provides a time varying electrical cuπent signal to one of the

coils 36. This time varying electrical cuπent induces a voltage in the other coil 36

whose magnitude varies as the separation distance between coils 36 varies. As ink is

used, the opposing side wall portions of reservoir 22 collapse together, changing the

electromagnetic coupling or mutual inductance of the coil pair. This change in coupling

is sensed by controller 32, which infers an ink level as a result. Additionally, controller

32 also makes a continuity check when ink container 12 is installed by determining if

electrical continuity exists between the two contact pads 54 leading to one of the coils

36.

Each ink container 12 has unique ink container-related aspects that are

represented in the form of data provided by information storage device 34. This data is

provided from ink container 12 to printing system 10 via memory device 34

automatically without requiring the user to reconfigure printer 10 for the particular ink

container 12 installed. Memory device 34 has a protected section, a write-once section,

and a multiple write/erase section. When the cartridge 12 is first installed in printer 10,

controller 32 reads ink container information such as the manufacturer identity, part

identification, system coefficients, service mode and ink supply size. Printing system 10

15 energizes one of coils 36 and reads an initial receiving coil voltage from the other

(receiving) coil 36. This initial receiving coil voltage from receiving coil 36 is

indicative of the full state of ink container 12. The printing system control electronics

then records a parameter onto the protected portion of memory device 34 that is

indicative of the initial receiving coil voltage. The printing system control electronics

then initiates a write protect feature to assure that the information in the protected

portion of memory is not altered.

The write once section is a portion of memory which can be written to by

controller 32 only one time. The multiple write/erase section allows data to be written

to this section more than once. Writing over data in this section is used to erase

previously stored data.

Upon insertion of ink container 12 into printing system 10, controller 32 reads

parameter information from memory device 34 for controlling various printing

functions. For example, controller 32 uses parameter information to compute an

estimate of remaining ink. If the ink remaining is less than a low ink threshold volume,

a message is provided to the user indicating such. Further, when within the ink

container 12 is below a threshold volume, controller 32 can disable printing system 10

to prevent operation of printhead 14 without a supply of ink. Operating printhead 14

without ink can result in reduction of printhead reliability or catastrophic failure of

printhead 14.

16 In operation, controller 32 reads initial volume information from memory device

34 associated with ink container 12. As ink is used during printing, the ink level is

monitored by controller 32, and memory device 34 is updated to contain information

relating to remaining ink in ink container 12. Controller 32 thereafter monitors the level

of deliverable ink in ink container 12 via memory device 34. In a prefeπed

embodiment, data is transfeπed between printer 10 and memory device 34 in serial

fashion using a single data line relative to ground.

In a prefeπed embodiment, the volume information includes the following: (1)

initial supply size data in a write protected portion of memory, (2) coarse ink level data

stored in write once portion of memory and (3) fine ink level data stored in a write/erase

portion of memory. The initial supply size data is indicative of the amount of

deliverable ink initially present in ink container 12.

The coarse ink level data includes a number of write once bits that each

coπespond to some fraction of the deliverable ink initially present in ink container 12.

In a first prefeπed embodiment, eight coarse ink level bits each coπespond to one-

eighth of the deliverable ink initially in ink container 12. In a second prefeπed

embodiment, to be used in the discussion that follows, seven coarse ink level bits each

coπespond to one-eighth of the deliverable ink initially present in ink container 12 and

one coarse ink level bit coπesponds to an out-of-ink condition. However, more or less

coarse bits can be used, depending on the accuracy desired for a coarse ink level

counter.

17 The fine ink level data is indicative of a fine bit binary number that is

proportional to a fraction of one-eighth of the volume of the deliverable ink initially

present in ink container 12. Thus, the entire range of the fine bit binary number is

equivalent to one coarse ink level bit. This will be further explained below.

Printing system 10 reads the initial supply size data and calculates the amount or

volume of deliverable ink initially present in ink container 12. The drop volume ejected

by the printhead 14 is determined by printing system 10 based on parameters. Using the

initial volume of deliverable ink in ink container 12 and the estimated drop volume of

printhead 14, the printing system 10 calculates the fraction of the initial deliverable ink

volume that each drop represents. This enables the printing system 10 to monitor the

fraction of the initial volume of deliverable ink remaining in ink container 12.

While printing, printing system 10 maintains a drop count equal to the number

of ink drops that have been ejected by printhead 14. After printing system 10 has

printed a small amount, typically one page, it converts the drop count to a fine bit binary

number value. This conversion utilizes the fact that the entire range of the fine bit

binary number coπesponds to one eighth of the initial volume of deliverable ink in ink

container 12. Each time the fine bit binary number value is fully decremented or

incremented, the printing system 10 writes to set one of the coarse ink level bits because

each of the coarse ink level bits are in the write once section of memory device 34 these

bits and coπesponding ink level value cannot be altered.

18 Printing system 10 periodically queries the coarse and fine ink level bits to

determine the fraction of the initial deliverable ink that is remaining in ink container 12.

Printing system 10 can then provide a "gas gauge" or other indication to a user of

printing system 10 that is indicative of the ink level in ink container 12. In a prefeπed

embodiment, the printing system provides a "low ink warning" when the sixth coarse

ink level bit is set. Also in a prefeπed embodiment, the printing system sets the eight

(last) coarse ink level bit when the ink container 12 is substantially depleted of ink.

This last coarse ink level bit is refeπed to as an "ink out" bit. Upon querying the coarse

ink level bits, the printing system interprets the setting of the ink out bit as an "ink out"

condition for ink container 12.

The volume is sensed by the inductive sensor coils 36 (Fig. 12) only during a

second phase of ink usage. During the first phase, both fine and coarse counters of are

used. Ink drops are counted and recorded in the fine counter portion of memory device

34. Each time the fine counter fully increments or decrements, another coarse counter

bit will be set. During the second phase, only the ink level sensor coils 36 are used. The

voltage output from the receiving coil 36 and is compared with the voltage level

indicated by the parameter recorded on memory device 34. A parameter indicative

voltage output is recorded on the write/erase portion of memory. Each successive

reading is compared with the previous reading as an eπor checking technique to allow

detection of coil malfunction.

19 In printing system 10, the transfer of data between printer 10 and memory

device 34 is in serial fashion on the single data line relative to ground. As explained

above, while the ink in ink container 12 is being depleted, memory device 34 stores data

which is indicative of its initial and cuπent states. Printer 10 updates memory device 34

to indicate the volume of ink remaining. When most or substantially all of the

deliverable ink has been depleted, printer 10 alters memory device 34 to allow ink

container 12 to provide an "ink out" signal. Printer 10 may respond by stopping

printing with ink container 12. At that point, the user will insert a new ink container 12

or an ink container which has been refurbished in accordance with this invention.

After being depleted of ink, the container 12 is potentially capable of further use

if replenished with a fresh supply of ink. However, these ink containers 12 are designed

for single use because of the information stored in the memory device which indicated

the amount of ink that was in the reservoir prior to being refilled. If refilled and

installed again on a printer, the data in the memory device 34 would still indicate the

volume of ink which it contained prior to refilling. The low ink warning which the

memory device 34 would signal would not be meaningful to the user because it would

be inaccurate. The user would be deprived of various advantages and safeguards of the

memory device. As a result, the reservoir is not designed for refilling. The present

invention as will be described with respect to Figs. 14-16 is a method and apparatus for

reusing these ink containers 12.

20 Refeπing to Fig. 14, a method of the present invention is illustrated for

refurbishing ink container 12. The method begins by providing an ink container 12 that

is at least partially depleted of an initial ink as indicated by step 170. The ink container

12 is depleted by supplying ink to one or more ink-jet printhead 14. As ink is provided

to the printhead 14 the memory device 34 associated with the ink container 12 is

updated with information for determining remaining ink in the ink container 12.

A source of new ink, different from the initial ink, is provided to fluid outlet 30

to refill fluid reservoir 22 as represented by step 172. Fluid reservoir 22 expands as ink

is provided, displacing air in pressure chamber 132. To relieve pressure in pressure

chamber 132, air is released through air inlet 28 as represented by step 174. The

memory device 34 is disabled so that the memory device 34 does not provide signals to

printing system 10 indicative of the depleted state as represented in step 176. A new

source of signals is provided that is indicative of an increased ink volume in fluid

reservoir 22 as represented in step 178. In a prefeπed embodiment, the new source of

signals is indicative of the increased volume of ink available for printing after refill step

172. Finally, in step 180, the ink container 12 is reinstalled, establishing fluidic, air, and

electrical connections between ink container 12 and printing system 10. The new ink in

refilled reservoir 22 is then made available to printhead 14 via conduit 20. In addition,

the new source of signals is made available to the printing system control electronics 32,

and can provide information to printing system control electronics 32 that enables

printing with the new ink provided by step 172.

21 Referring now to Figs. 15 and 16, a method and apparatus for filling ink

container 12 is depicted (steps 172 and 174 of Fig. 14). To refurbish ink container 12,

replacement ink is provided to collapsed reservoir 22. As replacement ink is provided,

reservoir 22 expands, displacing air in pressure chamber 132 between pressure vessel 24

and reservoir 22. To avoid pressurizing pressure chamber 132 and to maximize the rate

of ink flow, an air flow path is established through air inlet 28 from chamber 132 to a

location outside of pressure vessel 24.

When ink is introduced into ink container 12, sealing member 124 is moved

from a sealing position wherein it is in contact with septum 122 to an unsealed position

wherein it is displaced linearly into hollow boss 123 in a direction away from a distal

end of fluid outlet 30. At the same time, an opening or pathway is established in septum

122 by radially displacing septum 122. One way to do this is to insert a hollow conduit

such as a hollow needle through septum 122 such that the hollow conduit displaces

sealing member 124 linearly and displaces septum 122 radially. Next, a flow of ink is

established between a source of ink and reservoir 22. Ink then flows from the source of

ink, through the pathway in septum 122, past sealing member 124, through boss 123,

and to reservoir 22. To enhance the flow of ink the source of ink can be pressurized.

To allow rapid air removal from pressure chamber 132 during a refill operation,

an opening or pathway can be established in septum 128 by radially displacing septum

128. One way to do this is to insert a hollow conduit such as a hollow needle through

septum 128. Next, a flow of air is established, such that air flows from pressure

22 chamber 132, through hollow boss 129, through the opening in septum 128 and to an air

collection region. Among various alternatives, the air collection region can be outside

atmosphere or a source of vacuum. A source of vacuum applied to pressure chamber

132 will further enhance a flow of ink when refilling reservoir 22.

Referring now to Fig. 16, an exemplary embodiment of a refill apparatus for ink

container 12 is depicted. A refill adapter 140 is employed which preferably has an ink

sleeve 142 and a vent sleeve 144. Ink sleeve 142 and vent sleeve 144 are tubular

members with open lower ends for sliding over the ink outlet 30 and air inlet 28. Ink

sleeve 142 has a hollow needle 146 located therein which has a port 147 near its distal

end. A seal collar 148 sealingly engages needle 146 and moves slidingly between a

closed position, blocking port 147 and an open position which is shown in Figure 16. In

the open position, ink is allowed to flow through needle 146 and out port 147. A coil

spring 150 urges seal collar 148 to the closed position. A conduit 152 connects needle

146 to an ink reservoir or tank 156. A pump 154 is preferably connected into conduit

152 to pump ink from tank 156 under pressure. A hollow needle 158 or tubular member

is mounted in vent sleeve 144.

To refill, adapter 140 is placed on ink outlet 30 and air inlet 28. Needle 147

pierces the slit in septum 122 and pushes ball 124 downward to open the check valve.

Needle 158 pierces the slit in septum 128 and vents pressure chamber 132 to

atmosphere. Pump 154 is turned on to pump ink from tank 156 into reservoir 22 as

indicated by the arrows. Air in pressure chamber 132 being displaced by the expansion

23 in volume of reservoir 22 vents to atmosphere through needle 158. Once reservoir 22 is

refilled, adapter 140 is removed.

In addition to refilling with ink, refurbishment (steps 176 and 178 of Fig. 14)

also should be performed in regard to memory device 34 (Fig. 5) so that the benefits

previously provided by memory device 34 still exist. Refurbishment of memory device

34 is discussed in more detail in U.S. Patent Application Serial Number 09/034,875

incorporated herein by reference. The original memory device 34, which is located on

chassis 26, provides a first source of data signals indicative of an at least partially

depleted ink level state of ink container 12. More specifically and as explained above,

the memory device 34 includes coarse ink level data stored in a write once portion of

memory that has been altered by the printing system to reflect a reduced ink level or out

of ink condition. Consequently, refilling the ink container 12 results in alteration of the

amount of ink remaining but does not change the indicated coarse ink level. Therefore,

the memory device 34 does not provide accurate ink remaining information resulting in

improper low ink condition signals. In addition, because the refilled ink does not

necessarily have the same ink parameters (i.e., composition factors such as density,

colorants, solvents, additives, etc.) as those indicated by the memory device 34, then the

printing system 10 may not properly compensate for this refilled ink to ensure high print

quality.

To refurbish memory device 34, the pre-existing data in memory device 34 is

prevented from further communication with printer 10 when cartridge 12 is installed

24 again (step 176 of Fig. 14). In one technique, all of the data in memory device 34 is

erased. This can be accomplished by exposing the memory device 34 to an energy

source such as an x-ray or electric field. The energy source, if sufficient, resets the data

in memory device 34. The reservoir of ink container 12 is then refilled. Then memory

device 34 can be reprogrammed to reflect parameters of the refilled ink container 12.

When installed in the printing system 10 the printing system operates with the ink

container 12 in a manner similar to the original ink container.

In another refurbishment method, memory device 34 is disabled and replaced

with a nearly identical one or with an emulator. The new memory device 34 may be an

emulator or a substantial replica of the original memory device 34. An emulator is an

electronic circuit that is functionally equivalent to memory device 34 for exchanging

information with the printer 10. Although the emulator is functionally equivalent,

structurally this device may be very different. An emulator would likely have a portion

that functions as a memory and would likely provide information indicative of the

volume of the reservoir 22, the type of ink, color, etc. Optionally, unlike original

memory device 34, the emulator may be reset in a different manner such as whenever a

new ink supply is provided. Further, the emulator may be configured to provide

information to printer 10 that allows it to operate regardless of the actual condition of

ink in the in reservoir 22.

The new source of signals, such as an emulator or new memory device, should

be provided with the data required for proper operation of printer 10. The new source of

25 signals should be able to communicate with printer 10 over a single wire input/output in

serial fashion. This data provided by the new source of signals will be used by printer

10 to provide an indication of the volume of ink available.

In one technique for refurbishing ink container 12, the first memory device 34

will be removed from chassis 26 (Fig. 5). The substrate 86, along with memory device

34 and contact pads 80, may be pried off or otherwise removed as a unit from chassis

26. A new substrate 86, having a new memory device 34 or emulator and contact pads

80, may be secured to chassis 26 in the same place that held the original substrate 86,

memory device 34 and contact pads 80. The new substrate 86 could be secured by

fasteners or by adhesive. There is no need to remove volume sensing contact pads 78,

which are located on flexible circuit 82 and connected to inductor coils 36.

Alternately, a substrate 86 containing only a new set of contact pads 80 may be

mounted on chassis 26. The new memory device 34 or emulator may be mounted at

another place on ink container 12 or remotely and connected to the new set of contact

pads 80 by leads.

Another refurbishment method allows the original substrate 86, memory device

34 and contact pads 80 to remain in place. A new substrate 86, along with a new

memory device 34 and contact pads 80, will be bonded on top of the original memory

device 34 and contact pads 80. The material of substrate 86 is an electrical insulator.

Consequently, it will insulate the new contact pads 80 from the original contact pads 80

and the electrical traces in original substrate 86 which connected the original contact

26 pads 80 to original memory device 34. The original contact pads 80 will not be able to

electrically engage printer contacts 104 (Fig. 9) because they will be covered and

insulated from engagement by the new substrate 86.

In another refurbishment process, a usable portion of the original contact pads

80 remains in place and is electrically separated from the original memory device 34. In

this method, preferably a cut is made through the substrate 86 transversely across

contact pads 80 with a sharp object such as knife. The cut divides the substrate 86 into

retained and disposable portions, the retained portion of which contains a significant

portion of contact pads 80. The substrate 86 disposable portion contains memory device

34, and a small adjacent part of contact pads 80. This cut severs electrical continuity

between the four terminals of memory device 34 with the part of contact pads 80

contained on the substrate 86 retained portion. Although, the size of contact pads 80 on

the retained portion of substrate 86 would be smaller than the original contact pads 80,

they are of adequate size to mate with printer contacts 104 (Fig. 9).

Normally, one would then remove from chassis 26 the disposable portion of

substrate 86, along with the first memory device 34, and the part of contact pads 80

contained thereon. A new memory device 34 may then be mounted adjacent to or on

the original contact pads 80 contained on the retained substrate portion, with its

terminals connected to them. Optionally, the new memory device 34 could be mounted

elsewhere on housing 72 other than cavity 80 (Fig. 7) or even remotely from printer 10

and connected to original contact pads 80 by leads. Alternately, the contact pads 80 on

27 the retained portion of substrate 86 may be connected to leads that are attached to a

remotely located emulator or memory 34.

The invention has several advantages. These alternate methods of fluidically

refurbishing single-use ink containers allow them to be refilled so that it may be used

several times before being discarded. By electrically refurbishing ink container 12, the

volume of ink contained in reservoir 22 after refilling can be provided to printing

system 10 to allow printing system 10 to monitor usage of the refill ink. In the likely

event that the replacement ink used for refilling is different that the original ink (such as

different colorant, solvent, additive, etc., or different concentrations of constituents) this

change can be reflected by the new source of signals 34. When the ink container with

the new source of signals 34 is installed in printing system 10, the printing system 10

can also alert the user regarding the change in ink. This can be in the form of a message

displayed by the printing system 10 or a computer screen that is indicative of the type or

origin of ink installed. Such a message may indicate whether or not the ink contained in

reservoir 22 is of known origin or composition.

While the invention has been shown or described in only some of its forms, it

should be apparent to those skilled in the art that it is not so limited, but is susceptible to

various changes without departing from the scope of the invention.

28

Claims

What is claimed is:

1. A method for refilling a printer ink container which has a sealed housing, a

flexible ink reservoir located within the housing, an ink outlet in fluid communication

with the ink reservoir, and an air inlet in fluid communication with a space between the

housing and the ink reservoir, the method comprising:

(a) fluidically coupling an ink fitting to the ink outlet, the ink fitting being in fluid

communication with a source of ink;

(b) fluidically coupling an air fitting to the air inlet so that the air fitting is in fluid

communication with the space in the housing;

(c) refilling the ink reservoir with ink from the source of ink through the ink fitting

and ink outlet; and

(d) establishing a release of air from the space between the housing and the ink

reservoir and through the air inlet and air fitting.

2. The method of claim 1 wherein step (c) comprises refilling the ink reservoir

with a pressurized source of ink, and step (d) comprises releasing the air to atmosphere

as the ink reservoir is refilled with ink.

3. The method of claim 1 , wherein step (d) comprises applying a vacuum to

establish a flow of ink from the source of ink to the ink reservoir.

29

4. The method of claim 1 wherein the ink outlet has a protruding stem with a

septum, and wherein step (a) comprises connecting a hollow conduit to the source of ink

and pushing the hollow conduit through the septum.

5. The method of claim 4 wherein the protruding stem contains a sealing member

that is biased against the septum, and wherein step (a) further comprises displacing the

sealing member with the hollow conduit as the hollow conduit is pushed through the

septum.

6. The method of claim 1 wherein the air inlet has a protruding stem with a

septum, and wherein step (b) further comprises inserting a tubular member through the

septum.

7. A method for refilling a printer ink container having a sealed housing, a flexible

ink reservoir located within the housing, an ink outlet in fluid communication with the

ink reservoir, an air inlet in fluid communication with a space between the housing and

the ink reservoir, the air inlet having a protruding stem with a septum, the method

comprising:

(a) engaging and sealing an ink fitting to the ink outlet, the ink fitting being in fluid

communication with a pressurized source of ink;

30 (b) inserting a tubular member through the septum of the air inlet so that the tubular

member is in fluid communication with the space in the housing;

(c) refilling the ink reservoir with ink from the pressurized source of ink through the

ink fitting and the ink outlet; and

(d) establishing a release of air from the space between the housing and the ink

reservoir through the air inlet and tubular member, the air being released to atmosphere

as the ink reservoir is refilled with ink.

8. The method of claim 7 wherein the ink outlet contains a check valve with a ball

which is spring-biased, and wherein step (a) comprises providing a needle with the ink

fitting and opening the check valve with the needle of the ink fitting.

9. A method for refilling a printer ink container having a sealed housing, a flexible

ink reservoir located within the housing and having an ink outlet in fluid

communication with the ink reservoir, an air inlet in fluid communication with a space

between the housing and the ink reservoir, each of the ink outlet and the air inlet having

a protruding stem with a septum, the ink outlet further having a check valve, and the ink

container having a memory device connected to electrical contact pads mounted on the

housing for communicating information concerning characteristics of the ink in the ink

container to the printer, the method comprising:

31 (a) connecting an ink conduit to a source of ink and pushing the ink conduit through

the septum of the ink outlet, thereby opening the check valve and placing the ink

conduit in fluid communication with the source of ink;

(b) refilling the ink reservoir with ink from the source of ink through the ink conduit

and ink outlet; and

(c) refurbishing the memory device for providing enabling information to the

printer to enable the printer to operate.

10. The method of claim 9, further comprising establishing a release of air from the

space between the housing and the ink reservoir.

11. The method of claim 9 wherein step (c) comprises:

disabling the memory device such that it may no longer provide information to

he printing system; and

electrically connecting an electrical device to the ink container for providing

enabling information to the printer.

12. The method of claim 9, wherein step (c) comprises:

removing the memory device from the ink container by prying the memory

device from the ink container; and

32 securing a second memory device to the ink container for providing enabling information to the printer.

13. The method of claim 9 wherein step (c) comprises severing the memory device

from communication with the contact pads and connecting an electrical device to the

contact pads of the memory device for providing enabling information to the printer.

14. The method of claim 9 wherein step (c) comprises providing a second memory

device and a second set of contact pads on an insulating substrate and securing the

substrate on top of the first-mentioned memory device and contact pads.

15. The method of claim 9 wherein step (c) comprises erasing all of the information

in the memory device and reprogra ming the memory device.

16. The method of claim 9 wherein the memory device and the printer exchange

data in serial fashion over a single data line relative to a reference line, and wherein step

(c) comprises:

disabling the memory device such that the memory device may no longer

exchange data with the printer; and

33 electrically connecting an electrical device to the ink container which, when

connected to the printer, provides data in a serial fashion on the single data line of the

printer relative to the reference line.

17. A method of refurbishing an ink container, the ink container having a fluid

outlet including a septum, the ink container including a fluid reservoir, comprising:

displacing a sealing ball from an inside surface of the septum;

connecting a source of ink to the fluid outlet; and

establishing a flow of ink from the source of ink, past the sealing ball, and to the

fluid reservoir.

18. The method of claim 17, wherein the ink container includes a pressure chamber

formed by an outer housing, the method further comprising establishing a flow of air

between the pressure chamber and a region outside of the outer housing.

19. The method of claim 18, wherein the ink container includes an air inlet that

communicates between the pressure chamber and a region outside of the outer housing,

and the method including connecting a conduit to the air inlet and establishing an flow

of air from the pressure chamber, through the air inlet, and to the conduit to enhance the

flow of ink into the fluid reservoir.

34

20. A refurbished ink container adapted for installation into an inkjet printing

system, the ink container comprising:

a pressure vessel surrounding a supply of ink, the supply of ink including refill

ink; and

a source of signals that enables printing when the refurbished ink container is

releasably installed into the printing system.

21. The refurbished ink container of claim 20, wherein the supply of ink comprises

a collapsible reservoir, the pressure vessel defines a pressure chamber surrounding at

least a portion of the collapsible reservoir, the pressure chamber has been allowed to

expel air displaced during a refill operation of the collapsible reservoir.

22. A refurbished ink container adapted to be releasably installed into an inkjet

printing system, comprising:

a reservoir containing ink;

a fluid outlet including a septum having an inside surface and a sealing member

biased against the inside surface, the reservoir has been refilled by displacing the sealing

member away from the inside surface while connecting a source of refill ink to the fluid

outlet that flows from the source of ink, past the sealing member, and to the reservoir.

23. The refurbished ink container of claim 22, further comprising a source of signals

35 that enables printing when the refurbished ink container is releasably installed into the

printing system.

36