Ink Container with Metallized Traces for Accurate Level Sensing
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Solution Overview
Problem
Image reproduction devices face challenges in accurately determining ink levels due to manufacturing variations in printheads, leading to high development costs and cycle times for complex software and firmware solutions.
Innovation Solution
The use of position sensing elements within the ink container, featuring metallized traces on a polymer with a metal seed layer, allows for direct measurement of ink levels by varying electrical connections that change resistance with ink level changes, enabling accurate detection without being affected by printhead variations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If complex software and firmware solutions are developed to standardize ink level measurements across various printheads, then measurement precision is improved, but device complexity and development cost increase
Solution Approach 1:
The patent extracts the measurement function from the printhead to the ink container itself. By placing position sensing elements directly in the ink container, the measurement is performed at the source rather than relying on indirect back pressure measurements through the printhead, thereby eliminating the need for complex software/firmware standardization.
Solution Approach 2:
The patent introduces an intermediary measurement system (position sensing elements with metallized traces) that directly senses ink level in the container. This intermediary approach bypasses the problematic back pressure measurement path and provides direct, standardized measurements independent of printhead variations.
2Measurement precision
If complex software and firmware solutions are developed to standardize ink level measurements, then measurement precision is improved, but development cycle time increases
Solution Approach 1:
By extracting the measurement function from the printhead to the ink container, the patent eliminates the need for time-consuming software/firmware development and testing across multiple printhead variants, significantly reducing development cycle time.
Solution Approach 2:
The ink container with integrated position sensing elements performs self-measurement of ink levels, eliminating the need for external complex measurement systems and their associated development cycles.
3Device complexity
If back pressure measurement is used to determine ink level, then device complexity is reduced, but measurement precision deteriorates due to printhead manufacturing variations
Solution Approach 1:
The patent extracts the measurement point from the printhead (back pressure method) to the ink container (direct level sensing). This physical relocation of the measurement function eliminates sensitivity to printhead manufacturing variations while keeping the overall system relatively simple.
Solution Approach 2:
The patent replaces the mechanical back pressure measurement system with an electrical/electronic position sensing system using metallized traces and circuit elements, achieving higher precision without significantly increasing overall system complexity.
4Measurement precision
If standardization of ink level measurements is achieved through software and firmware, then measurement precision is improved, but manufacturing cost increases
Solution Approach 1:
By extracting the measurement function to the ink container with integrated position sensing elements, the patent eliminates costly software/firmware development and licensing requirements, reducing manufacturing costs while maintaining measurement precision.
Solution Approach 2:
The patent uses a cost-effective approach by integrating simple position sensing elements (metallized traces and basic circuit elements) into the ink container, which can be manufactured inexpensively compared to complex software/firmware solutions requiring extensive development and testing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method provides accurate ink level measurement, preventing low-quality printing and substrate wastage, while reducing development costs and cycle times by standardizing measurements across different printheads.
Implementation Method 1
The width of the electrical connection on an inside wall of the ink container gradually varies from a bottom of the ink container to its rim. As a result, even when there is a small change in the level of ink in the ink container, there is a large change in an effective resistance offered by the ink to the flow of electricity therethrough.
Data Source
AI summary
Aspects relating to an ink container for an image reproduction device are described herein. The ink container includes a body and an electrical connection. The body is formed by molding a polymer material having a metal seed layer. The electrical connection is formed by metallizing a plurality of traces in the metal seed layer. The electrical connection extends from an inside wall of the ink container to an outer wall. A width of the electrical connection on the inside wall of the ink container gradually varies from a bottom of the ink container to a rim.