Sealed Electrical Interconnects for Accurate Print Liquid 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 frequent replacements and increased printing costs.
Innovation Solution
A print liquid supply unit with a sensor housed in a thermoplastic container, using laser welding to create a waterproof seal and pass electrical connections through welded joints, ensuring accurate liquid level sensing and reducing ink supply changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensing methods are used to detect remaining print liquid, then the sensing system is simple, but the measurement precision deteriorates due to liquid bridging and environmental conditions
Solution Approach 1:
The patent replaces traditional mechanical or capacitive sensing methods with optical sensing. An optical sensor detects liquid level by measuring light transmission or reflection properties, which are not affected by liquid bridging or environmental humidity. This substitution maintains sensing simplicity while dramatically improving measurement precision in challenging printing environments.
2Reliability
If electrical connections are passed through welded joints in the container, then the sealing is maintained, but the manufacturing precision deteriorates due to the complexity of welding around interconnects
Solution Approach 1:
The patent segments the electrical interconnect structure into separate components: a rigid portion for electrical connection and a flexible portion for sealing. The rigid interconnect passes through the container wall, while the flexible interconnect extends into the sealed interior. This segmentation allows the welded joint to seal around the interconnect assembly without requiring complex welding geometries, maintaining both seal integrity and manufacturing precision.
Solution Approach 2:
The patent introduces a flexible interconnect as an intermediary element between the rigid electrical connection and the sealed interior space. This flexible portion acts as a mediator that can be sealed around by the welded joint, allowing electrical signals to pass through the container wall while maintaining the waterproof seal. The intermediary flexible interconnect simplifies the welding process compared to attempting to weld directly around rigid interconnects.
3Measurement precision
If the sensor is housed inside the reservoir, then the sensing is accurate, but the device complexity increases due to the need for sealed interconnects
Solution Approach 1:
The patent uses a flexible interconnect with a thin-walled structure that can be sealed within the welded joint. The flexible nature of this interconnect allows it to conform to the sealing geometry without requiring complex rigid structures. The thin-walled flexible design enables the interconnect to pass through the container wall and be sealed around by the welded joint, maintaining sensor accessibility while simplifying the overall interconnect structure.
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 waste, and minimizes the frequency of ink supply changes, thereby lowering printing expenses and maintaining print quality.
Implementation Method 1
using laser welding to create a waterproof seal
Data Source
AI summary
Examples of a print liquid supply unit are described herein. In some examples, the print liquid supply unit includes an electrical interconnect. In some examples, the electrical interconnect is sealed in a supply joint from an outside of the supply unit to an inside of the supply unit. In some examples, the supply joint is welded to join housing components of the supply unit.