Welded Sealed Interconnects for Accurate Print Liquid 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 frequent replacements and increased printing costs.
Innovation Solution
A print liquid supply unit with a sensor housed in a thermoplastic container, where an electrical interconnect is sealed through a welded joint using laser welding, allowing for precise liquid level sensing without additional materials, ensuring compatibility and robustness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additional sealing materials are used to seal the electrical interconnect through the welded joint, then the sealing reliability is improved, but the device complexity and manufacturing cost increase
Solution Approach 1:
The thermoplastic material itself performs the sealing function through its own deformation during welding. The material is heated above its glass transition temperature, becomes pliable, and conforms to seal around the electrical interconnect without requiring separate sealing components or additional materials.
Solution Approach 2:
The patent utilizes changes in the physical parameters of the thermoplastic material, specifically its glass transition temperature, to enable sealing. By heating the material above its glass transition temperature, it transitions from a rigid state to a pliable state that can deform and seal around the electrical interconnect, then solidifies upon cooling to maintain the seal.
2Productivity
If laser welding is used to seal the electrical interconnect, then the manufacturing efficiency is improved, but the manufacturing precision requirements increase
Solution Approach 1:
The patent utilizes changes in the physical parameters of the thermoplastic material, specifically its glass transition temperature, to enable sealing. By heating the material above its glass transition temperature, it transitions from a rigid state to a pliable state that can deform and seal around the electrical interconnect, then solidifies upon cooling to maintain the seal.
Solution Approach 2:
The patent replaces traditional mechanical sealing methods with laser-induced thermal welding. Instead of using mechanical pressure or assembly techniques to seal the electrical interconnect, the process uses localized laser heating to melt and fuse the thermoplastic material around the interconnect, creating a sealed joint.
3Measurement precision
If the sensor is accurately positioned to sense liquid level, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The sensor utilizes the natural optical properties of the print liquid and air to determine liquid level. By measuring light transmission or reflection through the transparent sidewall, the sensor self-determines the liquid level without requiring additional mechanical positioning mechanisms or complex calibration systems.
Solution Approach 2:
The patent utilizes optical property changes at the liquid-air interface to detect liquid level. The sensor detects changes in light transmission or reflection that occur when the liquid level changes, allowing accurate liquid level sensing through optical property variations rather than mechanical position changes.
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, maintaining print quality and reducing costs.
Implementation Method 1
the laser weldment seals the electrical interconnect through the welded joint
Implementation Method 2
heating the thermoplastic material above a glass transition temperature of the thermoplastic material
Data Source
Figure 1
Figure 2A~2D
Figure 3A~3C
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.