Narrow Ink Level Sensing Strip with Discrete Heaters
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Solution Overview
Problem
Existing liquid level sensors in printing systems are often expensive, complex, and provide low-resolution analog sensing, making them inefficient and inconvenient for accurately detecting ink levels, which can lead to device damage and customer dissatisfaction.
Innovation Solution
A low-cost, high-resolution liquid level sensing system with a narrow interface featuring a series of heaters and sensors arranged in pairs along a silicon strip, providing a high aspect ratio and dense sensor density to accurately detect ink levels without the need for expensive materials, suitable for corrosive liquids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional liquid level sensors are used in printing systems, then liquid level detection is provided, but the sensors are expensive, complex, and provide low-resolution analog sensing
Solution Approach 1:
The sensing interface is segmented into multiple discrete sensing components arranged in an array along the strip. Each sensing component independently detects liquid presence at its specific location, transforming a continuous analog sensing problem into discrete digital detections. This segmentation enables high-resolution liquid level measurement while keeping each individual sensing component simple in structure.
Solution Approach 2:
The patent replaces complex traditional mechanical or analog sensing mechanisms with a simplified array of discrete sensing components that provide direct digital output. This substitution eliminates the need for complex signal processing and analog-to-digital conversion circuits, reducing overall device complexity while improving measurement precision through the distributed array configuration.
2Reliability
If traditional liquid level sensors are used, then liquid level sensing is provided, but manufacturing costs are high
Solution Approach 1:
The patent employs sensing components that can be manufactured using inexpensive materials and processes. The thin-film heater and sensor array can be fabricated on flexible substrates using standard semiconductor manufacturing techniques, enabling mass production at low cost. This approach sacrifices the use of expensive specialized materials while maintaining reliable liquid level detection through the redundant array configuration.
Solution Approach 2:
The patent changes the physical parameters of the sensing system by using thin-film deposition techniques to create heater and sensor elements with specific resistance and thermal properties. By controlling the film thickness, material composition, and geometric patterns during manufacturing, the system achieves reliable sensing performance through parameter optimization rather than through expensive material selection.
3Measurement precision
If a narrow sensing interface with high aspect ratio is used, then sensor density is increased for accurate detection, but the interface area is reduced
Solution Approach 1:
The patent transitions from a two-dimensional sensing plane to a one-dimensional linear array by confining the sensing components to a narrow strip with high aspect ratio. This dimensional reduction concentrates the sensing elements along a single axis (the length of the strip), achieving high measurement precision through increased linear density rather than through increased total area. The narrow width of the strip minimizes the lateral dimension while the length provides sufficient resolution.
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
The system enables accurate, high-resolution liquid level detection, reducing manufacturing costs and improving customer satisfaction by providing reliable ink level monitoring, preventing device damage, and enhancing printing performance.
Implementation Method 1
The disclosed method comprises measuring the temperature along the heater with temperature sensors
Implementation Method 2
a temperature profile along the heater is determined by the geometry of the heater
Data Source
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AI summary
In one example in accordance with the present disclosure a liquid level sensing device is described. The device includes a carrier and a liquid level sensing device disposed on the carrier. The liquid level sensing interface has an aspect ratio of at least 1:50. A number of liquid level sensing components are disposed on the liquid level sensing interface. The number of liquid level sensing components detect a liquid level in a liquid container. The liquid level sensing device also includes an electrical interconnect to output data collected from the number of liquid level sensing components.