Print Liquid Reservoir Welding for Accurate Level Sensing
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Solution Overview
Problem
Accurately sensing the remaining amount of print liquid in a reservoir is challenging due to issues like liquid bridging and environmental conditions, leading to unnecessary reservoir changes and increased printing costs.
Innovation Solution
A print liquid supply unit with a sensor housed in a thermoplastic container, using welding techniques like laser or ultrasonic welding to create a waterproof seal, and employing a conductor sealed with a transmissive sealing material to maintain print quality and allow for precise liquid level sensing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a sensor is housed in a reservoir to sense liquid level, then liquid level sensing accuracy is improved, but the reservoir becomes vulnerable to damage from welding processes
Solution Approach 1:
The reservoir is divided into two separate components: a sensor housing that contains the sensor and electrical conductor, and a reservoir body that holds the print liquid. This segmentation allows the sensor housing to be positioned away from the welding zone while still enabling liquid level sensing, thus protecting the sensor from welding damage while maintaining sensing accuracy.
Solution Approach 2:
A sensor housing acts as an intermediary structure that protects the sensor and electrical conductor from the harsh welding environment. The housing is positioned such that it extends through the welding joint area, shielding the sensitive components from direct exposure to welding heat and stress while allowing the sensor to continue functioning.
2Device complexity
If a conductor is situated through a welding joint to house a sensor, then sensor integration is improved, but the welding process becomes more complex and may damage the conductor
Solution Approach 1:
The electrical conductor is installed through the sensor housing and connected to the sensor before the welding process begins. This preliminary action allows the conductor to be positioned and secured in place, and the sensor housing to be prepared for welding without the conductor interfering with the welding joint. The welding is then performed on the housing structure itself, avoiding direct exposure of the conductor to welding heat.
3Productivity
If thermoplastics are used for the container, then compatibility with high-volume manufacturing is improved, but environmental conditions may affect print quality
Solution Approach 1:
The patent specifies using thermoplastic materials with particular properties: they must be transparent to allow optical sensing of liquid level, have appropriate melting temperatures to withstand welding processes, and maintain dimensional stability under environmental conditions. By carefully selecting thermoplastic materials that meet these parameter requirements, the system achieves both high-volume manufacturing compatibility through injection molding and reliable print quality through controlled material properties.
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
Enhances the accuracy of print liquid level sensing, reduces unnecessary replacements, and maintains print quality by using thermoplastics compatible with high-volume manufacturing and environmental conditions.
Implementation Method 1
The first housing component may be joined to the second housing component to form a container to hold the print liquid. The first housing component may be welded to the second housing component along a supply joint
Implementation Method 2
the electrical conductor may be sealed with a transmissive sealing material. The transmissive sealing material may allow a welding laser to pass through the transmissive sealing material
Implementation Method 3
The transmissive sealing material may allow a welding laser to pass through the transmissive sealing material and weld the first housing component to the second housing component
Data Source
AI summary
Examples of a print liquid supply unit are described herein. In some examples, the print liquid supply unit includes a first housing component that is welded to a second housing component along a supply joint. In some examples, the print liquid supply unit also includes a conductor situated through the supply joint from an outside of the supply unit to an inside of the supply unit. In some examples, the conductor is sealed in the supply joint with a sealing material.