Liquid ink replenishment system for liquid electrographic imaging devices

Abstract

An ink replenishment system for supplying a working solution of an ink to an electrographic imaging device. A plurality of removable ink cartridges each have at least a first compartment containing ink concentrate and a second compartment. A fluid handling system couples the first compartment of each ink cartridge to a respective working solution reservoir. A controller controls the flow of ink concentrate from each ink cartridge and liquid carrier from a source of liquid carrier to maintain a working solution concentration of working solution in each of the working solution reservoirs. A return system fluidly couples each of the developer stations to the second compartment of the respective ink cartridges. Alternate embodiments include one compartment and three compartment cartridges, and locating the working solution reservoir in the removable cartridge.

Description

FIELD OF THE INVENTION

The present invention relates generally to a liquid replenishment system for a liquid electrographic imaging device.

BACKGROUND OF THE INVENTION

A liquid electrographic imaging system includes an imaging substrate onto which a developer liquid is delivered to develop a latent image. The imaging substrate may be a permanent image receptor or alternatively, may be a temporary image receptor. A liquid electrographic imaging system may be an electrostatic system having a dielectric material as the imaging substrate, or may take the form of an electrophotographic system having a photoreceptor as the imaging substrate. In an electrostatic system that makes use of a dielectric material, the latent image can be formed by selectively charging the dielectric substrate with an electrostatic stylus. In an electrophotographic system, the photoreceptor includes a photoconductive material that is uniformly charged, for example, with a corona charging device. A latent image can be formed on the photoreceptor by selectively discharging the photoreceptor with a pattern of radiation. A liquid electrophotographic imaging system with a photoreceptor will be discussed for purposes of example.

Several techniques have been developed over the years to adapt electrographic techniques to use multiple colors, such as disclosed in U.S. Pat. Nos. 3,832,170 (Nagamatsu et al.); 4,578,331 (Ikeda et al.); 4,728,983 (Zwadlo et al.); and 4,877,698 (Watson et al.). Color printers use three primary colors, typically cyan, magenta and yellow, and in addition, optionally, black. The toner may be a dry powder or a liquid.

The liquid ink (also referred to as a liquid toner or liquid developer) for an electrophotographic printing system normally includes solids or toner particles dispersed in a liquid carrier or solvent at a predetermined ratio. These two components deplete at different rates from the ink during printing. The relative component depletion rates are dependent on the percent coverage of the image produced by the imaging system and on other factors. For example, as the solids get transferred to the receptor material, the ratio of liquid carrier to solids increases, necessitating the addition of more solids to the ink. In images where the percent coverage is relatively low, liquid carrier is lost from the receptor material at a rate faster than the solids are depleted from the ink, requiring additional liquid carrier to be added to the ink to maintain the required ratio of solids to liquid carrier. Various systems have been made to deliver ink solids and liquid carrier to electrophotographic printers.

U.S. Pat. No. 5,208,637 (Landa) discloses a liquid toner replenishment system for an electrophotographic printer that does not have a separate liquid carrier replenishment system. When the density of the liquid toner in the mixing reservoir is below a first predetermined level, a motor is activated to add a measured amount of toner concentrate from a container to the respective toner reservoir, thereby increasing the toner particle concentration to the required level. Since the proportion of toner particles to liquid carrier in the container is less than the concentration carried out of the toner reservoir, an excess of liquid carrier is effectively added to the reservoir in excess of that removed by printing. This process causes the liquid level in the tank to rise slightly each time the toner concentrate is added. No mechanism is provided for adding liquid carrier to the reservoirs in the event the concentration of toner particles exceeds a predetermined level.

U.S. Pat. No. 3,973,699 (Cook) discloses a liquid dispensing apparatus utilizing a double-acting piston. When the level of liquid developer drops to a predetermined level, a drive unit is energized and the liquid developer is forced from the cartridge. The pressure drop caused by movement of the piston is employed to draw waste developer from a sump into a chamber within the cartridge. The liquid dispensing apparatus of Cook does not provide separate sources of ink concentrate or liquid carrier in order to maintain the required ratio of those components in the developer tray.

U.S. Pat. No. 3,876,282 (Schon et al.) discloses a container for supplying liquid developer in an electrophotographic copier. The container of Schon holds both developer concentrate and developer separated by a sliding separating wall. Developer concentrate is displaced into the correspondingly enlarged liquid developer chamber by movement of the sliding separating wall. Although the concentration of the liquid developer can be increased by the addition of developer concentrate, the container of Schon does not provide a source of liquid carrier to lower the concentration of the liquid developer when necessary.

BRIEF SUMMARY OF THE INVENTION

The present invention is directed to an ink replenishment system for supplying a working solution of an ink to an electrographic imaging device. The image data is transmitted to a photoreceptor material. The liquid ink is deposited on the photoreceptor material corresponding to the image data. The ink solids are then transferred to a receiving medium, such as paper or a film.

In a first embodiment, the ink replenishment system delivers ink concentrate and a liquid carrier to a plurality of working solution reservoirs coupled to developer stations in the electrographic imaging device. A plurality of removable ink cartridges each have at least a first compartment containing ink concentrate and a second compartment. A fluid handing system couples the first compartment of each ink cartridge to a respective working solution reservoir. A controller controls the flow of ink concentrate from each ink cartridge and liquid carrier from a source of liquid carrier to maintain a working solution concentration of working solution in each of the working solution reservoirs. A return system directs both overflow and printed down ink from each of the developer stations to the second compartment of the respective ink cartridges.

In one embodiment, the source of liquid carrier comprises a removable liquid carrier cartridge. Alternatively, the source of liquid carrier can be a liquid carrier reservoir in the electrographic imaging device. Before being attached to the electrographic imaging device, the second compartments of the ink cartridges initially contain liquid carrier, working solution, or is empty.

The relative size of the first and second compartments preferably change dynamically. The second compartment preferably has a volume sufficient to receive the working solution from the working solution reservoir. In one embodiment, the first compartment comprises a collapsible container located within the second compartment. The second compartment preferably contains a quantity of liquid carrier sufficient for making an initial working solution in a working solution reservoir.

In one embodiment, the ink cartridges comprise three compartments. The working solution reservoirs can be the third compartment in each of the respective ink cartridges. In alternate embodiments, the third compartment initially contains either liquid carrier or is empty before being connected to the electrographic imaging device.

At least one sensor is provided for monitoring a concentration of the working solution. At least one of the compartments includes an agitator. In one embodiment, the agitator is magnetically coupled to an actuator located on the electrographic imaging device. Each of the working solution reservoirs preferably includes an overflow line fluidly coupled to the second compartment of the respective ink cartridge. In one embodiment, the ink concentrate in each ink cartridge is a different color. Self-sealing valves preferably form an interface between the first and second compartments and the electrographic imaging device.

The removable ink cartridges can be oriented generally horizontal, vertical or at various angles within the electrographic printing device. A key tab is included on each ink cartridge positioned to engage with respective detectors on the electrographic imaging device. In one embodiment, the color key tabs comprise a data storage device containing data selected from a group consisting of color of the ink concentrate, concentration of the ink concentrate to liquid carrier, date the ink cartridge was manufactured, remaining life of the ink cartridge, number of prints made from the cartridge, and manufacturer identification codes.

In another embodiment, the ink replenishment system comprises a plurality of removable ink cartridges each containing ink. The fluid handling system couples the cartridges to the respective developer stations. A controller controls the flow of ink from each ink cartridge and liquid carrier from the source of liquid carrier to maintain a working solution concentration of working solution at each of the developer stations. A return system directs both overflow and printed down ink from each of the developer stations to the second compartment of the respective ink cartridges. The ink may be either ink concentrate or working solution.

In one embodiment, the ink cartridge compartment defines an upper region and a lower region. A first self-sealing valve is fluidly coupled to the upper region of the compartment. A second self-sealing valve is fluidly coupled to the lower region of the compartment, whereby upon separation of the ink solids from the liquid carrier, the first valve fluidly communicates with the liquid carrier and the second valve fluidly communicates with the ink solids. In one embodiment, the return system includes a plurality of staging tanks for temporarily retaining printed down ink before transferring it to the respective ink cartridges.

In another embodiment, the ink replenishment system includes a plurality of fill ports fluidly coupled to the working solution reservoirs. The controller controls the flow of ink and liquid carrier from the source of liquid carrier to maintain a working solution concentration of working solution in each of the working solution reservoirs. The return system fluidly couples each of the working solution reservoirs to removable containers. In one embodiment, the removable containers comprise the ink cartridges.

The present invention also relates to a method of delivering ink concentrate and a liquid carrier to a plurality of working solution reservoirs coupled to respective developer stations in an electrographic imaging device. The method includes coupling a plurality of removable ink cartridges each having at least a first compartment containing ink concentrate and a second compartment to the electrographic imaging device. The flow of ink concentrate from a plurality of ink cartridges and liquid carrier from a source of liquid carrier is controlled to maintain a working solution concentration of working solution in each of a plurality of respective working solution reservoirs. The working solution from the working solution reservoirs is directed to respective developer stations. Each of the developer stations is fluidly coupled to the second compartments of the respective ink cartridges.

As used here;

"liquid carrier" refers to a solvent or other liquid into which the film-forming solids or film-forming toner particles are dispersed. "concentration" refers to the ratio of ink solids in a volume of liquid ink. "electrographic" refers to electrostatic, electrophotographic and ionographic. "imaging device" refers to printers, copiers, fax machines, and other image duplication systems. "ink solids" refers to film-forming solids or film-forming toner particles. "ink" or "liquid ink" refers to ink solids dispersed in a liquid carrier. "ink concentrate" refers to ink at a concentration greater than the working solution concentration. "ink replenishment system" refers to a method and apparatus that permits the concentration of the working solution to be either increased or decreased. "printed down ink" or "depleted ink" refers to ink at a concentration of ink solids below the working solution concentration. "photoreceptor material" refers to electrophotographic imaging materials onto which a film forming ink can be deposited. "substantially dry ink" refers to ink on a receptor material with about 50 volume % solids or greater. "working solution" refers to ink at about the working solution concentration. "working solution concentration" refers to a concentration of ink solids suitable for developing a latent image on a receptor material in an electrographic imaging device.

BRIEF DESCRIPTION OF THE SEVERAL VIEW OF THE DRAWINGS

The foregoing advantages, construction and operation of the present invention will become more readily apparent from the following description and accompanying drawings in which:

FIG. 1 is a diagrammatic illustration of an electrophotographic method and apparatus.

FIG. 2 is an expanded diagrammatic illustration of a single developer station used in the apparatus illustrated in FIG. 1.

FIG. 3 is a schematic illustration of an ink replenishment system utilizing a two compartment ink cartridge for an electrographic imaging device in accordance with the present invention.

FIG. 4 is a side sectional view of an two compartment ink cartridge in accordance with the present invention.

FIG. 5 is a side sectional view of an alternate two compartment ink cartridge in accordance with the present invention.

FIG. 6 is a side sectional view of another alternate two compartment ink cartridge in accordance with the present invention.

FIG. 7 is a side sectional view of another alternate two compartment ink cartridge in accordance with the present invention.

FIG. 8 is a schematic illustration of an ink replenishment system utilizing a one compartment ink cartridge for an electrographic imaging device in accordance with the present invention.

FIG. 9 is a schematic illustration of an alternate ink replenishment system utilizing a one compartment ink cartridge for an electrographic imaging device in accordance with the present invention.

FIG. 10 is a schematic illustration of an ink replenishment system utilizing a three compartment ink cartridge for an electrographic imaging device in accordance with the present invention.

FIG. 11 is an exploded perspective view of an ink cartridge design in accordance with the present invention.

FIG. 12 is an exploded perspective view of a cap for an ink cartridge in accordance with the present invention.

FIG. 13 is a sectional view of one embodiment of an ink cartridge and a cartridge assembly interface.

FIG. 14 is a perspective view of the cartridge assembly interface of FIG. 13.

FIG. 15 is a perspective view of an ink cartridge bay in accordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Liquid electrophotography is a technology that produces or reproduces an image on paper or other desired receiving medium. Liquid electrophotography uses liquid inks that may be black or which may be of different colors for the purpose of plating solid material onto a surface in a well controlled and image-wise manner to create the desired prints. Typically, liquid inks used in electrophotography are substantially transparent or translucent to radiation emitted at the wavelength of the latent image generation device so that multiple image planes can be laid over one another to produce a multi-colored image constructed of a plurality of image planes with each image plane being constructed with a liquid ink of a particular color.

Typically, a colored image is constructed of four image planes. The first three planes are constructed with a liquid ink in each of the three subtractive primary printing colors, yellow, cyan, and magenta. The fourth image plane uses a black ink that need not be transparent to radiation emitted at the wavelength of the latent image generation device. Various methods and devices for electrophotographic printing are disclosed U.S. Pat. No. 5,650,253 (Baker et al.) entitled Method and Apparatus having Improved Image Transfer Characteristics for Producing an Image on Receptor Medium such as Plain Paper.

In the illustrated embodiment, the process involved in liquid electrophotography can be illustrated with reference to FIGS. 1 and 2. Light sensitive, photoreceptor material 10 is arranged on or near the surface of a mechanical carrier, such as drum 12. Drum 12 rotates in the clockwise direction of FIG. 1 moving a given location of photoreceptor material 10 past various stationary components which perform an operation relative to photoreceptor material 10 or an image formed on drum 12. Alternatively, the photoreceptor material 10 can be a belt structure.

In FIG. 1, as drum 12 rotates, photoreceptor material 10 moves past erase lamp 14. When photoreceptor material 10 passes under erase lamp 14, radiation 16 from erase lamp 14 impinges on the surface of photoreceptor material 10 causing any residual charge remaining on the surface of photoreceptor material 10 to "bleed" away. Thus, the surface charge distribution of the surface of photoreceptor material 10 as it exits erase lamp 14 is quite uniform and nearly zero depending upon the photoreceptor.

As drum 12 continues to rotate and photoreceptor material 10 next passes under charging device 18, a uniform positive or negative charge is imposed upon the surface of photoreceptor material 10. In a preferred embodiment, the charging device 18 is a positive DC corona. Typically, the surface of photoreceptor material 10 is uniformly charged to around 600 volts depending on the capacitance of photoreceptor. Charging prepares the surface of photoreceptor material 10 for an image-wise exposure to radiation by laser scanning device 20 as drum 12 continues to rotate.

Wherever radiation from laser scanning device 20 impinges on the surface of photoreceptor material 10, the surface charge of photoreceptor material 10 is reduced significantly while areas on the surface of photoreceptor material 10 which do not receive radiation are not appreciably discharged. Areas of the surface of photoreceptor material 10 which receive some radiation are discharged to a degree that corresponds to the amount of radiation received. This results in the surface of photoreceptor material 10 having a surface charge distribution which is proportional to the desired image information imparted by laser scanning device 20 when the surface of photoreceptor material 10 exits from under laser scanning device 20. As drum 12 continues to rotate, the surface of photoreceptor material 10 engages with one of the developer stations 22a, 22b, 22c, 22d, each corresponding to a primary color (i.e., yellow, magenta, cyan) and optionally black.

The operation of individual developer stations 22a, 22b, 22c, 22d can be more readily understood by reference to FIG. 2. The first color plane is developed by bringing the developer station 22a into position adjacent to the photoreceptor material 10. The other three developer stations 22b, 22c, 22d preferably do not engage with the photoreceptor during development of the first color plane. Ink 24a is applied to the surface of image-wise charged photoreceptor material 10 in the presence of an electric field which is established by placing development roll 26a, illustrated as a roller, near the surface of photoreceptor material 10 and imposing a bias voltage on development roll 26a. Ink 24a consists of positively charged "solid," but not necessarily opaque, toner particles of the desired color for this portion of the image being printed. The "solid" material in the liquid ink, under force from the established electric field, migrates to and plates upon the surface of photoreceptor material 10 in areas 28a where the surface voltage is less than the bias voltage of development roll 26a. The "solid" material in the liquid ink will migrate to and plate upon the development roll in areas 30 where surface voltage of photoreceptor material 10 is greater than the bias voltage of development roll 26a. Excess ink not sufficiently plated to either the surface of photoreceptor material 10 or to development roll 26a is returned to the developer station 22a. The method for removing excess ink in the illustrated embodiment is a "crowned squeegee roller" described in U.S. Patent Application entitled Squeegee Apparatus and Method for Removing Developer Liquid From an Imaging Substrate and Fabrication Method, U.S. Ser. No. 08/811,660 filed Mar. 4, 1997.

The ink 24a is dried by drying mechanism 32a which may include a roll, vacuum box or curing station. Drying mechanism 32a substantially transforms ink 24a into a substantially dry film 28a. The excess ink 24a returns to developer station 22a for subsequent processing. The "solid" portion 28a (film) of ink 24a plated upon the surface of photoreceptor material 10 matches the image-wise charge distribution previously placed upon the surface of photoreceptor material 10 by laser scanning device 20 and, hence, is an image-wise representation of the desired image to be printed.

Film 28a is further dried by drying mechanism 34. Drying mechanism 34 may be a passive device, using for example active air blowers, heater, vacuum, coronas, or may be other active devices such as rollers. In a preferred embodiment, drying mechanism 34 is a drying roll or image conditioning roller, such as described in U.S. Pat. Nos. 5,420,675 and 5,552,869. The process is then repeated for developer stations 22b, 22c, 22d to deposit an image plane or film 28b, 28c, 28d of the other colors.

The film 28a, 28b, 28c, 28d representing the desired image to be printed is then transferred, either directly to the receiving medium 36 to be printed, or preferably and as illustrated in FIG. 1, indirectly by way of transfer rollers 38. Transfer is effected by differential tack of film 28a, 28b, 28c, 28d and transfer rollers 38. The preferred mechanism for image transfer is disclosed in U.S. Pat. No. 5,650,253 entitled Method and Apparatus Having Improved Image Transfer Characteristics for Producing an Image On a Receptor Medium such as Plain Paper. Typically, heat and pressure are utilized to fuse the image to medium 36. The resultant "print" is a full color hard copy manifestation of the image information written by laser scanning device 22, the colors represented by inks 24a, 24b, 24c, 24d.

In one embodiment, the drying mechanisms 32a, 32b, 32c, 32d are squeegee rolls described in U.S. patent application Ser. No. 08/811,660 entitled Apparatus and Method for Removing Developer Liquid from an Imaging Substrate and Fabrication Method, filed Mar. 4, 1997. Development rolls (also known as electrodes) 26a, 26b, 26c, 26d are kept clean by a developer cleaning roller as described in U.S. Pat. No. 5,596,398 entitled Apparatus and Method for Cleaning Developer From an Imaging Substrate. Any further excess ink is removed by an additional roller described in U.S. Pat. No. 5,713,068, entitled Apparatus and Method for Removing Excess Ink from a Imaging Substrate. An exemplary developer apparatus is described in detail in U.S. Pat. No. 5,576,815. Developer stations 22a, 22b, 22c, 22d are similar to that described in U.S. Pat. No. 5,300,990 (Thompson et al.).

Two-Compartment Ink Cartridge

FIG. 3 is a schematic illustration of a liquid replenishment system 40 for an electrographic imaging device 42 having a plurality of developer stations 44a, 44b, 44c, 44d. The developer stations 44c and 44d are not shown in detail for the sake of simplicity. The components and operation of the developer stations 44c, 44d are substantially as described in connection with developer stations 44a, 44b. It will be understood that the liquid ink handling system for each developer station is preferably separate and complete, although the liquid carrier 61 is preferably supplied to each developer station from a single liquid carrier cartridge or container 60.

Developer stations 44a, 44b each have development rolls 46a, 46b and drying mechanisms 48a, 48b positioned opposite a photoreceptor material 50. In the embodiment illustrated in FIG. 3, the photoreceptor material 50 is in the form of a continuous belt, rather than the drum illustrated in FIGS. 1 and 2. In the described embodiment, the developer stations 44a, 44b each have associated working solution reservoirs 52a, 52b for retaining respective working solutions 54a, 54b. The reservoirs 52a, 52b can either be part of the developer stations 44a, 44b or separate components.

A liquid carrier cartridge 60 is fluidly coupled to the developer stations 44a, 44b by a solvent supply line 62 and a solvent supply pump 64. Liquid carrier 61 can be directed to each of the developer stations 44a, 44b (44c, 44d) and a condenser 68 by the solenoid valve 66. Condenser 68 is positioned to recover evaporated liquid carrier 61 lost within the electrographic imaging device 42. A condenser return line 70 fluidly couples the condenser 68 to the liquid carrier cartridge 60. Alternatively, liquid carrier collected in the condenser 68 can be collected and removed from the electrographic imaging device 42. Cartridge 60 can either be permanently incorporated into the electrographic imaging device 42 or can be a removable cartridge, such as ink cartridges 80a, 80b.

FIG. 3 illustrates ink cartridges 80a, 80b, 80c, 80d coupled to respective developer stations 44a, 44b (44c, 44d not shown). Since ink cartridges 80c, 80d are shown schematically, the discussion will focus on ink cartridges 80a, 80b. The ink cartridges 80a, 80b, 80c, 80d may contain different color inks, inks of the same color, but at different concentrations or with different levels of charge carriers, or combinations thereof.

Ink cartridges 80a, 80b each have a first compartment 82a, 82b containing ink concentrate 84a, 84b and a second compartment 86a, 86b containing liquid carrier 61. Although FIG. 3 shows the cartridges in a horizontal configuration, it is possible to orient them vertically or on an angle. Agitators 90a, 90b are preferably provided in each of the first compartments 82a, 82b. Drive mechanisms 180a, 180b, such as a motor, are preferably positioned on the electrographic imaging device 42 to releasably couple to the agitators 90a, 90b (see generally FIG. 13).

The first compartments 82a, 82b and second compartments 86a, 86b are fluidly coupled to the working solution reservoir 52a, 52b by separate ink/carrier supply lines 92a, 92b and pumps 94a, 94b. Solenoid valves 96a, 96b are provided for selectively delivering concentrate 84a, 84b or liquid carrier 61 to the working solution reservoirs 52a, 52b. Valves 104a, 104b can alternatively direct the working solutions 54a, 54b to the second compartments 86a, 86b of the ink cartridges 80a, 80b or to the development rolls 46a, 46b on the developer stations 44a, 44b, respectively.

Overflow lines 98a, 98b fluidly couple the working solution reservoirs 52a, 52b to the second compartments 86a, 86b of the respective cartridges 80a, 80b. Return lines 100a, 100b and working solution pumps 102a, 102b fluidly couple the working solution reservoirs 52a, 52b to the second compartments 86a, 86b. As used herein, the various components of the return system direct both overflow and printed down ink from each of the working solution reservoirs 52a, 52b to the second compartments 86a, 86b of the respective ink cartridges 80a, 80b. Alternatively, the working solutions 54a, 54b can gravity drain into the second compartments 86a, 86b.

In one embodiment, the liquid carrier 61 in the second compartments 86a, 86b is mixed with a portion of the ink concentrates 84a, 84b in the respective first compartments 82a, 82b to form initial working solution 54a, 54b in the working solution reservoirs 52a, 52b. Once the liquid carrier 61 is removed from the second compartments 86a, 86b, the second compartments 86a, 86b are available for receiving fluids from the overflow lines 98a, 98b or the return lines 100a, 100b. In alternate embodiments, the second compartments 86a, 86bmay be manufactured to be either initially empty or filled with a working solution 54a, 54b. The relative size of the first and second compartments 82a, 86a and 82b, 86b preferably changes dynamically to accommodate decreasing volumes of ink concentrate 84a, 84b and increasing volumes of printed down ink from the overflow lines 98a, 98b or return lines 100a, 100b (see FIGS. 4-7).

During printing, pumps 102a, 102b supply working solution 54a, 54b to the development rolls 46a, 46b. In the illustrated embodiment, sensors 106a, 106b monitor the concentration of ink solids in the working solutions 54a, 54b. Concentration of ink solids can be measured by evaluating by a variety of properties, such as magnetic or optical properties, or the conductivity of the working solutions 54a, 54b. Alternate sensors can monitor the optical density on the photoreceptor 50 or the optical density on the receiving medium 36 (see FIG. 1). Liquid level sensors 110a, 110b optionally monitor the level of working solution 54a, 54b in the reservoirs 52a, 52b. Sensors 112a, 112b may optionally be included in the cartridges 80a, 80b to monitor concentration, fluid level, etc. The measuring techniques discussed above may be used with any of the embodiments discussed herein. Various sensors and measuring devices are disclosed in U.S. Pat. Nos. 4,222,497; 4,310,238 (Mochizuki et al.); 5,294,891 (Saklikar et al.); 5,447,056 (Foote) and PCT publications WO 94/01756 and WO94/01809.

The working solution reservoirs 52a, 52b preferably include agitators 107a, 107b. Overflow of working solution 54a, 54b from the development rolls 46a, 46b flows back into the respective working solution reservoirs 52a, 52b.

Controller 108 monitors the sensors 106a, 106b, 110a, 110b to determine if the ink solids concentration in the working solutions 54a, 54b is within an acceptable range and/or whether the level of working solution 54a, 54b in the reservoirs 52a, 52b is within a preferred range. The controller can either activate pumps 94a, 94b (to add additional ink concentrate 84a, 84b), activate pump 64 (to add additional liquid carrier to the working solutions 54a, 54b), or both. Overflow lines 98a, 98b allow excess working solutions 54a, 54b to drain into the second compartments 86a, 86b of the respective ink cartridges 80a, 80b. The overflow lines 98a, 98b provide a relatively constant maximum volume of working solution 54a, 54b in the working solution reservoirs 52a, 52b.

In one embodiment, once the first compartment 82a is empty, the controller 108 activates the working solution pump 102a and the valve 104a to direct the contents of the working solution reservoir 52a to the second compartment 86a of the removable cartridge 80a. The controller 108 can determine that the first compartment 82a is depleted by a variety of techniques, such as the sensor 112a (sensor 112b in cartridge 80b) or the inability to increase the concentration of ink solids in the working solution 54a after a predetermined number of attempts. In another embodiment, controller 108 counts the number of pixels of a given color that have been deposited on the photoreceptor material 50 during the development process. Total pixel count is correlated to ink solids consumption to estimate the life of the cartridges 80a, 80b. Pixel counting techniques are advantageous because they can predict when the cartridge 80a, 80b will be empty.

The present liquid replenishment system 40 provides a return system for capturing, storing, and recovering any overflow of working solution or liquid carrier from the working solution reservoir 52a. Additionally, the contents of the liquid carrier can be removed using a removable cartridge 60 or can be emptied into the working solution reservoir 52a and subsequently pumped using the working solution pump 102a into the second compartments 86a of the removable ink cartridge 80a. Upon completion of the ink replenishment cycle, the depleted ink cartridge 80a containing the printed down ink and/or used carrier is ejected from the electrographic imaging device 42 for refilling, replenishment and/or recycling. The same procedure can be applied to the other ink cartridges 80b, 80c, 80d.

The liquid replenishment system 40 of FIG. 3 also permits the second compartments 86a, 86b of the ink cartridge 80a, 80b to store the working solution 54a, 54b upon special circumstances, such as electrographic imaging device shutdown, servicing, moving, shipping, and/or other conditions, for which it is desirable to have all ink-related fluids removed from the electrographic imaging device 42. The working solution 54a, 54b can later be returned to the working solution reservoirs 52a, 52b through the working solution supply lines 92a, 92b. In addition, it provides a method of recovering such fluids for reuse upon normal electrographic imaging device start-up following such circumstances. The second compartments 86a, 86b may also be used for storing the working solution in cases such as normal shutdown, power save, or a sleep mode.

In another embodiment, the first compartments 82a, 82b contain the ink concentrate 84a, 84b and the second compartments 86a, 86b contain working solution 54a, 54b. The working solution 54a, 54b is pumped to the respective working solution reservoir 52a, 52b. As discussed above, printed down ink can be deposited in the now empty second compartments 86a, 86b for recycling. Concentrate 84a, 84b and/or liquid carrier 61 can be added during operation of the imaging device to maintain the working solution concentration. In this embodiment, the liquid carrier reservoir 60 is preferably a removable cartridge.

FIG. 4 is a schematic illustration of an exemplary two-compartment ink cartridge 130 in which the first compartment 82 is defined by a collapsible container 132, such as a polymeric bag. The second compartment 86 is defined by the volume between the flexible container 132 and the outer container 134. As the contents of the first compartment 82 are removed from the cartridge 130, the relative size of the first compartment 82 decreases in proportion to the increase in the volume of second compartment 86. The container 132 is attached to an inside surface 136 in fluid communication with a valve port 138. Various methods can be used to ensure that the container 132 collapses from the rear 142 towards the valve port 138, such as the use of an elastomeric bag or orienting the cartridge so that the valve port 138 is at a lower elevation. Valves 138, 146 are fluidly connected to the ink carrier supply line 92. Valve 144 is fluidly connected to the return line 100.

FIG. 5 is an alternate two-compartment ink cartridge 150 having a piston 152 that separates the first compartment 82 from the second compartment 86. The piston 152 is moved by the flow of the fluids in the cartridge 150 during electrographic imaging device operation. As discussed in connection with FIG. 4, the piston 152 keeps the contents of the first compartment 82 near the valve 138. Valves 138, 146 are fluidly connected to an ink carrier supply line 92. Valve 144 is fluidly connected to a return line 100. Alternatively, the piston 152 could be driven in a variety of ways, including by the pressure difference (pneumatic or vacuum from pumping of the ink concentrate), a screw drive, an actuator rod, or other external forces such as a spring. The piston 152 can either ride against an inside surface of the container 154 or along an optional inner cylinder 156. Use of the optional inner cylinder 156 allows the container 154 to have a non-uniform profile.

FIG. 6 illustrates an alternate two-compartment ink cartridge 160 utilizing an elastic or plastic membrane 162 to separate the first compartment 82 from the second compartment 86. Tube 161 ensures that the membrane 162 will expand from the rear of the cartridge 163 toward the valves 144, 146. The reference numerals 162a, 162b, 162c correspond to the elastic membrane 162 of FIG. 6 in various stages of inflation/deflation. The first compartment 82 is connected to the valve 138. Valve 146 is optionally connected to an ink carrier supply line 92. Valve 144 is fluidly connected to a return line 100.

FIG. 7 is another embodiment of a two-compartment ink cartridge 170 utilizing an expandable plastic or elastomeric container 172 to define the first compartment 82. The volume of the second compartment 86 grows as the volume of ink concentrate decreases from the first compartment 82, thus enabling it to accept increasing amounts of printed down ink from the electrographic imaging device 42. The embodiments of FIGS. 4-7 allow for a proportional change in the size of the compartments 82, 86.

Single Compartment Ink Cartridge

FIG. 8 is a schematic illustration of an alternate liquid replenishment system 200 for use with single compartment ink cartridges 202a, 202b. In a first embodiment, ink concentrate 84a, 84b is delivered to the working solution reservoirs 52a, 52b through an ink supply lines 204a, 204b by pumps 206a, 206b. The working solution reservoirs 52a, 52b may or may not be attached to the associated developer stations 44a, 44b. The working solution 54a, 54b can be advanced to the developer rolls 46a, 46b by various pump mechanisms (not shown). Carrier supply pump 208 and carrier supply lines 210 supply liquid carrier 61 from the cartridge 60 to the working solution reservoirs 52a, 52b and the condenser 68. The liquid carrier supply lines 210 are preferably positioned by the rolls 46a, 46b, 48a, 48b to facilitate cleaning.

Overflow lines 212a, 212b and return lines 214a, 214b fluidly couple the working solution reservoirs 52a, 52b to respective staging tanks 216a, 216b to hold printing fluids until the ink cartridges 202a, 202b are empty. Agitators 90a, 90b are preferably provided in the cartridges 202a, 202b. Actuators 180a, 180b are preferably positioned on the electrographic imaging device 42 to releasably couple to the agitators 90a, 90b (see generally FIG. 13).

Sensors 106a, 106b communicate the concentration of ink solids of the working solutions 54a, 54b to the controller 108. The controller 108 can activate one or more of the ink supply pumps 206a, 206b to increase the concentration of ink solids in the working solutions 54a, 54b. Alternatively, the controller 108 can activate the liquid carrier supply pump 208 to add liquid carrier, thereby decreasing the concentration of ink solids in the working solution 54a, 54b. Solenoid valve 207 permits liquid carrier to be selectively delivered to one or more of the developer stations 44a, 44b, 44c, 44d. Overflow lines 212a, 212b maintain a generally constant maximum volume in the working solution reservoirs 52a, 52b. When ink cartridges 202a, 202b are empty, the contents of the respective staging tanks 216a, 216b are emptied into the cartridges 202a, 202b for recycling. In the preferred embodiment, there are separate staging tanks fluidly coupled to each of the developer stations 44a, 44b, 44c, 44d, rather than a central staging tank for all developer stations.

In an alternate embodiment, overflow or drainage from the working solution reservoirs 52a, 52b goes directly back into the respective ink cartridges 202a, 202b. The ink concentrate 84a, 84b preferably has a low free charge of preferably less than 60%, more preferably less than 40%, and most preferably less than 30%. Free charge is measured as a ratio of the conductivity of the liquid carrier as it appears in the liquid ink and the conductivity of the liquid ink as a whole. See U.S. Pat. No. 5,652,282. Therefore, when the overflow ink or printed down ink flows back into the cartridges 202a, 202b, minimal free charge is being added to the concentrate 84a, 84b. Consequently, the printed down ink does not have to be kept separate from the ink concentrate 84a, 84b. As the printed down ink flows into the cartridges 202a, 202b, the concentration of the ink in the ink cartridges 202a, 202b is likely to decrease. When the controller 108 determines that one or more of the ink cartridges 202a, 202b are exhausted, the cartridges 202a, 202b are removed for recycling. Alternatively, the printed down ink can be sent to a removable container (not shown) for removal and/or recycling.

In yet another embodiment, working solution 54a, 54b (or ink concentrate) is supplied to the working solution reservoirs 52a, 52b through fill ports 220a, 220b. Liquid carrier 61 can be added to the working solution reservoirs 52a, 52b as required. In one embodiment, the electrographic imaging device 42 does not contain a replenishment system for replenishing the working solution 54a, 54b. The empty cartridges 202a, 202b (that previously contained the working solutions) are then attached to the electrographic imaging device 42 at the location of the ink cartridges 202a, 202b. When the controller 108 determines via sensors 106a, 106b that the concentration of one of the working solutions 54a, 54b is below a predetermined level, that working solution is drained into the respective container 202 for removal and recycling. Alternatively, waste container can be used in place of the empty cartridges 202a, 202b. In this embodiment, the ink supply lines 204 and ink supply pumps 206 are not required.

In yet another embodiment, the cartridges 202a, 202b initially contain working solution 54a, 54b before being attached to the electrographic imaging device 42. The working solution 54a, 54b is pumped directly to the developer rolls 46a, 46b. Overflow drains directly back into the cartridges 202a, 202b through return lines 214a, 214b. No working solution reservoirs 52a, 52b or staging tanks 216a, 216b are required. Additional liquid carrier 61 can be added to the cartridges 202a, 202b through the return lines 214a, 214b. No source of concentrate 84a, 84b is provided.

FIG. 9 illustrates an alternate ink replenishment system 240 (generally shown in FIG. 8) that would be used with gel inks, such as disclosed in U.S. Pat. No. 5,652,282. Initially, the ink is mixed and could be immediately used. Over time, the ink solids will substantially separate from the liquid carrier 61a, 61b and form a gel layer 252a, 252b. The gel layer 252a, 252b will have a substantially higher ink solids concentration than the original ink. The liquid carrier layer 61a, 61b will be substantially free of ink solids, but may contain charge directors. The liquid carrier 61a, 61b can optionally be pumped to a liquid carrier reservoir 60. The liquid carrier reservoir 60 may either be permanent or a removable cartridge.

The time required for the separation of the gelled ink concentrate from the liquid carrier will vary between about 30 minutes and about 72 hours, depending upon the formulation of the ink. Liquid carrier supply lines 254a, 254b are positioned to supply liquid carrier 61a, 61b from the cartridges 250a, 250b to the respective working solution reservoirs 52a, 52b. Separate ink solids supply lines 256a, 256b are positioned to supply gelled ink concentrate from the cartridges 250a, 250b to the respective working solution reservoirs 52a, 52b. Valves 258a, 258b allow the controller 108 to select either liquid carrier 61a, 61b or gelled ink concentrate 252a, 252b to be pumped to the working solution reservoirs 52a, 52b. In one embodiment, printed down ink is retained in staging tanks 216a, 216b so as to not contaminate the liquid carrier 61a, 61b in the ink cartridges 250a, 250b. When the working solution 54a, 54b is exhausted, the printed down ink in the staging tanks 216a, 216b is returned to the cartridges 202a, 202b for removal and recycling.

Three-Compartment Ink Cartridge

FIG. 10 is a schematic illustration of an ink replenishment system 300 utilizing three-compartment ink cartridges 302a, 302b. In one version of the embodiment of FIG. 10, the developer stations 44a, 44b do not include a working solution reservoirs, such as discussed below. Rather, one or more compartments of the ink cartridges 302a, 302b operate as working solution reservoirs.

In one embodiment, compartments 304a, 304b initially hold ink concentrate 84a, 84b, compartments 306a, 306b hold working solutions 54a, 54b, and compartments 308a, 308b hold liquid carrier 61. In the illustrated embodiment, the working solutions 54a, 54b have a greater concentration of charge carrier than the ink concentrate 84a, 84b. Working solution supply lines 312a, 312b and pumps 311a, 311b direct the working solutions 54a, 54b to the respective developer stations 44a, 44b. The liquid carrier 61 initially in compartments 308a, 308b is pumped to the liquid carrier cartridge 60 by a liquid carrier reservoir fill lines 314 and pumps 315. Once empty, the compartments 308a, 308b can be used for receiving printed down ink 310a, 310b. As will be discussed below with regard to the various embodiments, the compartments 306a, 306b, 308a, 308b may initially be used for other functions.

The concentration of the working solution 54a, 54b in the working solution compartments 306a, 306b can be measured by sensors 112a, 112b. Alternatively, sensors 106a, 106b in lines 312a, 312b can monitor the concentration of the working solution 54a, 54b delivered to the developer stations 44a, 44b. When the concentration of the working solutions 54a, 54b are not within established parameters, the controller 108 may add liquid carrier 61 through the liquid carrier supply lines 318 to the working solution reservoirs 306a, 306b. Alternatively, additional ink concentrates 84a, 84b from the compartments 304a, 304b can be added to the working solution reservoirs 306a, 306b through lines 317a, 317b. If there is insufficient volume in the compartments 306a, 306b, the solenoid valves 320a, 320b can direct a portion of the working solutions 54a, 54b to the compartments 308a, 308b through the lines 321a, 321b prior to the addition of ink concentrates 84a, 84b or liquid carrier 61 to the respective compartments 306a, 306b. Overflow from the developer stations 44a, 44b is directed through overflow lines 316a, 316b to the respective working solution compartments 306a, 306b. The overflow lines 316a, 316b can optionally include staging tanks, such as illustrated in FIG. 8.

The first embodiment of FIG. 10 has the advantage that the process of replenishing, circulating, and disposing of ink and liquid carrier is performed substantially within the ink cartridges 302a, 302b. The ink cartridges 302a, 302b can be ejected and reinserted at generally any time during the printing process with minimal disruption to the fluid management algorithms or the electrographic imaging device's fluid "housekeeping" (managing depleted ink and liquid staging). Additionally, the ink cartridges 302a, 302b can be ejected quicker once the ink concentrate 84a, 84b is depleted because less fluid needs to be transferred to the compartments 308a, 308b. The developer stations 44a, 44b do not require working solution reservoirs. Finally, the fluids in the various compartments 304, 306, 308 can have differing levels of charge carriers.

In yet another embodiment, the compartments 306a, 306b initially contain liquid carrier 61 that is pumped to the liquid carrier cartridge 60 by a liquid carrier reservoir fill lines 314 and pumps 311. The compartments 308a, 308b are initially empty so that they are immediately ready to receive printed down ink 310a, 310b. Working solution 54a, 54b is mixed in the compartments 306a, 306b by combining ink concentrate 84a, 84b from the compartments 304a, 304b and liquid carrier 61 from the liquid carrier cartridge 60 through the lines 316a, 316b. As discussed above, the developer stations 44a, 44b may or may not have a working solution reservoir, since the compartments 306a, 306b serve as a working solution reservoirs 54a, 54b.

Two-Compartment Ink Cartridge

FIG. 11 is an exploded perspective view of an exemplary two-compartment ink cartridge 400 according to the present invention. In the illustrated embodiment, outer shell 402 is a unitary structure defining a continuous internal volume. The outer shell 402 has a primary portion 404 and a secondary portion 406. The secondary portion 406 assists in aligning the cartridge within the imaging device 42. In one embodiment, the secondary portion 406 includes a plurality of slots 412a, 412b, 412c, 412d for receiving a color key tab 414. As will be discussed below, the color key tab 414 can be used for a variety of functions, such as identifying the cartridge, preventing misalignment and improper insertion.

The outer shell 402 has a primary opening 416 for receiving internal container 418 to define multiple compartments. In the illustrated embodiment, the internal container 418 is a flexible bag. The internal container 418 has an opening 420 configured to attach to a flange 422 on seal disk assembly 424. The volume defined by the internal container 418 comprises the first compartment. The volume defined between the internal container 418 and the outer shell 402 comprises the second compartment.

Seal disk assembly 424 has a recess (see FIG. 14) for receiving an impeller 426. As will be discussed below, the impeller 426 is preferably magnetically coupled to an actuator on the electrographic imaging device to provide agitation. Alternatively, a direct mechanical coupling may be used. Seal disk assembly 424 has three valve ports 428, 430, 432, each of which preferably include a valve, such as illustrated in FIG. 13. The valve ports are further described in commonly assigned patent application entitled Valve Assembly for Ink Cartridge (docket No. 53745USA3A) filed on the same date herewith. Valve port 428 fluidly communicates with the first compartment defined by the internal container 418. Valve ports 430 and 432 fluidly communicate with the second compartment. Valve port 430 is for receiving printed down ink. Valve port 432 is for supplying the contents of the second compartment (i.e., liquid carrier) to the electrographic imaging device 42. Closure device 434 retains the seal disk 424 to the outer shell 402.

Cap 440 extends over the seal disk assembly 424. The cap 440 has a series of holes 444 through which the ports 428, 430, 432 can be accessed, a valve access door 442, and a center hole 446 for interfacing actuator 180 with the impeller 426 (see FIG. 13). In an alternate embodiment, slots 412a, 412b, 412c, 412d are formed on the cap 440 for receiving a color key tab 414.

The valve access door 442 limits access to ports 428, 430, 432 (see FIG. 11) until the cartridge 400 is inserted onto the electrographic imaging device 42. The valve access door 442 is normally closed when the cartridge 400 is outside the electrographic imaging device 42. When in this position, the valve access door 442 is locked shut by a latch 445 that is captured by a latch retainer 447 on the cap 440.

When the cartridge 400 is inserted, a latch release key 448 located on the electrographic imaging device 42 releases the latch 445 from the latch retainer 447. At this point, a cam follower 450 on the valve access door 442 lines up with a cam 452 located on the electrographic imaging device 42. As the ink cartridge 400 is inserted into the electrographic imaging device 42, the cam follower 450 moves down cam 452 (see FIG. 15). Since the cam 452 is fixed on the electrographic imaging device, the valve access door 442 rotates as the cam follower 450 on the door 442 moves along the cam 452. Eventually, the valve access door 442 is completely opened and the ports 428, 430, 432 can be engaged with the electrographic imaging device 42. When the ink cartridge 400 is ejected, the ports 428, 430, 432 disengage and the cam follower 450 on the valve access door 442 moves along the cam 452 until the valve access door 442 is in the closed position. Once the door 442 reaches a closed position, the latch 445 engages with the latch retainer 447, locking the door 442 into position over the ports 428, 430, 432. In another embodiment, the latch release key 448 is omitted. The latch 445 and latch retainer 447 comprises a detent system that is overcome by the force generated by the cam 452.

FIG. 13 is a cross-sectional side view of an ink cartridge 400 generally as discussed above partially inserted into an ink cartridge bay 472 of a electrographic imaging device housing 474. At one end of the ink cartridge bay 472 is an opening 476 through which the ink cartridge 400 is inserted and removed. The opening 476 preferably has a shape corresponding to a cross section of the ink cartridge 400 (see FIG. 15) to facilitate the correct orientation. At the other end is a cartridge interface assembly 478 for fluidly coupling the ink cartridge 400 with the electrographic imaging device 42. The cartridge interface assembly 478 includes a shroud 483 for receiving cap 440 and valve ports 484, 486 and 488 (see FIG. 15) for fluidly coupling with the valve ports 428, 430, 432, respectively, on the ink cartridge 400. Each of the valve ports is preferably self sealing so as to prevent leakage from the ink cartridge 400 or the electrographic imaging device 42 when the cartridge 400 is removed.

Drive magnet 490 is coupled to the actuator 180 by shaft 492 positioned to magnetically couple with impeller magnet 494 to drive impeller 426. The impeller magnet 494 is preferably contained within the outer shell 402 to minimize leakage of ink. The drive magnet 490 preferably has a shape complementary to the shape of the impeller magnet 494. The magnetic coupling between the magnets 490, 494 is sufficient to transfer rotational energy to the impeller 426, but is easily decoupled when the ink cartridge 400 is removed from the electrographic imaging device 42.

The ink cartridge 400 has a longitudinal axis 480 that corresponds with longitudinal axis 482 on the cartridge interface assembly 478. As the ink cartridge 400 is advanced along longitudinal axis 480, the cap 440 is received by the shroud 483 and the magnets 490, 494 couple. The valve ports 428, 430, 432 and mating valve ports 484, 486, 488 are fully open when the ink cartridge 400 is fully engaged with the ink cartridge bay 472. Latch 495 optionally engages with edge 496 of the cartridge 400 to retain the cartridge in the ink cartridge bay 472.

Detector 498 is mounted in the ink cartridge bay 472 in a position to engage with the color key tab 414. The detector 498 can have a slot positioned to receive the color key tab 414 only if it is in the correct slot 412a, 412b, 412c, 412d on the outer shell 402. That is, the detector slot prevents cartridges of the wrong color from being fully inserted into the ink cartridge bay 472. The detector can include a switch that senses the presence of the color key tab 414, such as a mechanical switch or optical sensor. In another embodiment, the color key tab 414 includes a data storage device, such as a microchip with read/write capabilities or bar code, containing information about the ink cartridge 400, that can be read by the detector 498. The data storage device could include information about the color of the ink concentrate, concentration of the ink concentrate to liquid carrier, date the ink cartridge was manufactured, remaining life of the ink cartridge, number of prints made from the cartridge, and manufacturer identification codes.

FIG. 14 is a perspective view of the cartridge interface assembly 478 fully engaged with the disk seal assembly 424. The rear view of the disk seal assembly 424 illustrates the flange 422 for receiving the internal container 418 (see FIG. 11) surrounding the impeller 426 and rear side of valve port 428. The rear side of valve ports 430, 432 are positioned to fluidly couple with the region between the outer shell 402 and the internal container 418 (see FIG. 11).

FIG. 15 is a perspective cut-away view of an ink cartridge bay 500 in accordance with the present invention. The ink cartridge bay 500 is typically located within the electrographic imaging device housing 502. The electrographic imaging device housing 502 includes a front panel 504 having a series of ink cartridge openings 506 that have a shape corresponding to a cross section of ink cartridges 508. In the illustrated embodiment, the opening 506 has a pair of opposing protrusions 510, 512 that correspond to the transition 514, 516 between primary portion 509 and secondary portion 511 on the ink cartridge 508, so that the ink cartridges 508 are properly oriented within the ink cartridge bay 500.

Opposite the openings 506 at the far end of the ink cartridge bay 500 is a electrographic imaging device bulkhead 520 having a series of receptacle assemblies 522 positioned to engage with the ink cartridges 508 (see FIG. 13). In addition to the three mating valve ports 484, 486, 488 and drive magnet 490 discussed above, the receptacles 522 include the latch key release 448 and cam 452 illustrated in FIG. 12 to activate the valve access door 442. The sensor 498 is positioned to engage with the color key tab 414.

Liquid Ink

Liquid ink found particularly suitable for use in the present invention include gel organosols that exhibit excellent imaging characteristics in liquid immersion development. For example, the gel organosol inks exhibit low bulk conductivity, low free phase conductivity, low charge/mass and high mobility, all desirable characteristics for producing high resolution, background free images with high optical density. In particular, the low bulk conductivity, low free phase conductivity and low charge/mass of the inks allow them to achieve high developed optical density over a wide range of ink solids concentrations, thus improving their extended printing performance relative to conventional inks.

When used in electrophotography, these liquid inks on development form colored films which transmit incident radiation such as, for example, near infrared radiation, consequently allowing the photoconductor layer to discharge. In contrast, non-film forming inks comprising non-coalescent particles scatter a portion of the incident light. Non-coalesced ink particles therefore result in the decreasing of the sensitivity of the photoconductor to subsequent exposures and consequently there is interference with the overprinted image.

The liquid carrier is typically oleophilic, chemically stable under a variety of conditions, and electrically insulating. Electrically insulating means that the liquid carrier has a low dielectric constant and a high electrical resistivity. Preferably, the liquid carrier has a dielectric constant of less than 5, and still more preferably less than 3. Examples of suitable liquid carriers are aliphatic hydrocarbons (n-pentane, hexane, heptane and the like), cycloaliphatic hydrocarbons (cyclopentane, cyclohexane and the like), aromatic hydrocarbons (benzene, toluene, xylene and the like), halogenated hydrocarbon solvents (chlorinated alkanes, fluorinated alkanes, chlorofluorocarbons and the like), silicone oils and blends of these solvents.

Preferred liquid carriers include paraffinic solvent blends sold under the names Isopar G liquid, Isopar H liquid, Isopar K liquid and Isopar L liquid (manufactured by Exxon Chemical Corporation, Houston, Tex.). The preferred liquid carrier is Norpar-12 liquid, also available from Exxon Corporation.

The optimal weight ratio of resin to colorant in the toner particles is on the order of 1/1 to 20/1, most preferably between 10/1 and 3/1. The total dispersed "solid" material in the liquid carrier typically represents 0.5 to 20 weight percent, most preferably between 0.5 and 3 weight percent of the total liquid ink composition.

Inks for use in the present invention include a soluble charge control agent, sometimes referred to as a charge director, to provide uniform charge polarity of the toner particles. The charge director may be incorporated into the toner particles, may be chemically reacted to the toner particle, may be chemically or physically adsorbed onto the toner particle (resin or pigment), and may be chelated to a functional group incorporated into the toner particle, preferably via a functional group comprising the stabilizer. The charge director acts to impart an electrical charge of selected polarity (either positive or negative) to the toner particles. Any number of charge directors described in the art may be used herein; preferred positive charge directors are the metallic soaps. See U.S. Pat. No. 3,411,936, Rotsman et al. The preferred charge directors are polyvalent metal soaps of zirconium and aluminum, preferably zirconium octoate. Exemplary inks, liquid carriers, ink solids, and charge directors are described with more particularity in U.S. Pat. Nos. 5,652,282 and 5,698,616.

All patent and patent applications, including those disclosed in the background of the invention, are hereby incorporated by reference. The present invention has now been described with reference to several embodiments thereof. It will be apparent to those skilled in the art that many changes can be made in the embodiments described without departing from the scope of the invention. Thus, the scope of the present invention should not be limited to the structures described herein, but rather by the structures described by the language of the claims, and the equivalents of those structures.

Claims

1. An ink replenishment system for delivering ink concentrate and a liquid carrier to a plurality of working solution reservoirs coupled to developer stations in an electrographic imaging device comprising:

a plurality of removable ink cartridges each having at least a first compartment containing ink concentrate and a second compartment;

a source of liquid carrier;

a fluid handing system coupling the first compartment of each ink cartridge to the respective working solution reservoirs;

a controller for separately controlling the flow of ink concentrate from each ink cartridge and liquid carrier from the source of liquid carrier to each of the working solution reservoirs to maintain a working solution concentration of working solution in each of the working solution reservoirs; and

a return system fluidly coupling each of the developer stations to the second compartment of the respective ink cartridges.

2. The system of claim 1 wherein the source of liquid carrier comprises a removable liquid carrier cartridge.

3. The system of claim 1 wherein the source of liquid carrier comprises a liquid carrier reservoir in the electrographic imaging device.

4. The system of claim 1 wherein the second compartments of the ink cartridges contain a fluid selected from the group consisting of liquid carrier, working solution, and charge director.

5. The system of claim 1 wherein the relative size of the first and second compartments change dynamically.

6. The system of claim 1 wherein the second compartment comprises a volume sufficient to receive the working solution from the working solution reservoir.

7. The system of claim 1 wherein the first compartment comprises a collapsible container located within the second compartment.

8. The system of claim 1 wherein the second compartment contains at least a quantity of liquid carrier sufficient for forming an initial working solution in a working solution reservoir.

9. The system of claim 1 wherein the working solution reservoirs comprise a third compartment in each of the respective ink cartridges.

10. The system of claim 1 wherein the ink cartridges comprise three compartments.

11. The system of claim 10 wherein the third compartments of the ink cartridges contain a fluid selected from the group consisting of liquid carrier, working solution, and charge director.

12. The system of claim 10 wherein the third compartment is initially empty.

13. The system of claim 10 wherein the relative size of at least two of the compartments changes dynamically.

14. The system of claim 1 further comprising at least one sensor for monitoring a concentration and/or level of the working solution.

15. The system of claim 1 wherein at least one of the compartments further comprises an agitator.

16. The system of claim 1 wherein each of the removable ink cartridges comprises an agitator magnetically coupled to an actuator located on the electrographic imaging device.

17. The system of claim 1 wherein each of the working solution reservoirs further comprise an agitator.

18. The system of claim 1 wherein each of the working solution reservoirs further comprises an overflow line fluidly coupled to the second compartment of the respective ink cartridges.

19. The system of claim 1 wherein the removable ink cartridges are oriented generally horizontal within the electrographic imaging device.

20. The system of claim 1 wherein the removable ink cartridges are oriented generally vertical within the electrographic imaging device.

21. The system of claim 1 further comprising a key tab on each ink cartridge positioned to engage with respective detectors on the electrographic imaging device.

22. The system of claim 21 wherein the detector signals to the controller misalignment of the ink cartridge within the electrographic imaging device.

23. The system of claim 21 wherein the key tabs comprise a data storage device.

24. The system of claim 23 wherein the data storage device contains data selected from a group consisting of color of the ink concentrate, concentration of the ink concentrate to liquid carrier, date the ink cartridge was manufactured, remaining life of the ink cartridge, number of prints made from the cartridge, and manufacturer identification codes.

25. The system of claim 1 wherein the ink concentrate in at least two of the ink cartridges comprises a different color.

26. The system of claim 1 further comprising a plurality of self-sealing valves forming an interface between the first and second compartments and the electrographic imaging device.

27. An ink replenishment system for delivering ink to a plurality of developer stations in an electrographic imaging device comprising:

a plurality of removable ink cartridges each containing liquid ink;

a source of liquid carrier;

a fluid handling system coupling the cartridges to the respective developer stations;

a controller for separately controlling the flow of ink from each ink cartridge and liquid carrier from the source of liquid carrier to working solution reservoirs, respectively, to maintain a working solution at a working solution concentration at each of the developer stations; and

a return system fluidly coupling each of the developer stations to one or more removable waste containers.

28. The system of claim 27 wherein the ink comprises working solution.

29. The system of claim 27 wherein the ink comprises ink concentrate.

30. The system of claim 27 wherein the source of liquid carrier comprises a removable liquid carrier cartridge.

31. The system of claim 27 further comprising a sensor for monitoring the working solution concentration.

32. The system of claim 27 wherein the removable waste containers comprise the ink cartridges without the ink.

33. The system of claim 27 further comprising a key tab on each ink cartridge positioned to engage with respective detectors on the electrographic imaging device.

34. The system of claim 27 wherein the ink in at least two of the ink cartridges comprises a different color.

35. The system of claim 27 wherein each of the ink cartridges comprises:

a compartment defining an upper region and a lower region;

a first valve fluidly coupled to the upper region of the compartment; and

a second valve fluidly coupled to the lower region of the compartment, whereby upon separation of the ink solids from the liquid carrier, the first valve fluidly communicates with the liquid carrier and the second valve fluidly communicates with ink concentrate.

36. The system of claim 27 wherein the return system further comprises a plurality of staging tanks for temporarily retaining printed down ink before transferring it to the respective removable waste containers.

37. An ink replenishment system for delivering ink to a plurality of working solution reservoirs fluidly coupled to developer stations in an electrographic imaging device comprising:

a fill port for adding the ink to each of the working solution reservoirs;

a source of liquid carrier;

a controller for separately controlling a flow of the ink and the liquid carrier from the source of liquid carrier to each of the working solution reservoirs to maintain a working solution concentration of working solution in each of the working solution reservoirs; and

a return system fluidly coupling each of the working solution reservoirs to one or more removable waste containers.

38. A method of delivering ink concentrate and a liquid carrier to a plurality of working solution reservoirs coupled to respective developer stations in an electrographic imaging device comprising:

coupling a plurality of removable ink cartridges to the electrographic imaging device, each of the ink cartridges having at least a first compartment containing ink concentrate and a second compartment;

separately controlling the flow of the ink concentrate from the plurality of ink cartridges and liquid carrier from a source of liquid carrier to each of the working solution reservoirs to maintain a working solution concentration of a working solution in each of the working solution reservoirs;

directing the working solution from the working solution reservoirs to the respective developer stations; and

fluidly coupling each of the developer stations to the second compartment of the respective ink cartridges.

39. The method of claim 38 wherein the source of liquid carrier comprises a removable liquid carrier cartridge.

40. The method of claim 38 wherein the second compartments of the ink cartridges initially contain liquid carrier.

41. The method of claim 38 wherein the second compartments of the ink cartridges initially contain working solution.

42. The method of claim 38 wherein the relative size of the first and second compartments changes dynamically.

43. The method of claim 38 wherein the first compartment comprises a collapsible container located within the second compartment.

44. The method of claim 38 wherein the second compartment initially contains a quantity of liquid carrier and the method further comprises directing the liquid carrier and a portion of the ink concentrate to the working solution reservoir to form a working solution.

45. The method of claim 38 wherein the second compartment comprises the working solution reservoir and the method further comprises fluidly coupling the first compartment to the second compartment.

46. The method of claim 38 wherein the ink cartridges comprise three compartments.

47. The method of claim 38 further comprising agitating at least one of the ink concentrate or the working solution.

48. The method of claim 37 further comprising directing printed down ink to the second compartment.

49. The method of claim 38 further comprising orienting the removable ink cartridges horizontal within the electrographic printing device.

50. The method of claim 38 further comprising orienting the removable ink cartridges vertical within the electrographic printing device.

51. The method of claim 38 further comprising locating a key tab on each ink cartridge positioned to engage with respective detectors on the electrographic imaging device.

52. The method of claim 38 wherein the ink concentrate in at least two of the ink cartridges comprises different colors.

53. The method of claim 38 further comprising engaging a plurality of valves at an interface between the ink cartridges and the electrographic imaging device.

54. An ink replenishment system for delivering ink concentrate and a liquid carrier to a plurality of working solution reservoirs coupled to developer stations in an electrographic imaging device comprising:

a plurality of removable ink cartridges each having at least a first compartment containing ink concentrate and a second compartment comprising the working solution reservoir;

a source of liquid carrier;

a fluid handing system coupling the first compartment of each ink cartridge to the respective working solution reservoirs;

a controller for separately controlling the flow of ink concentrate from each ink cartridge and liquid carrier from the source of liquid carrier to each of the working solution reservoirs to maintain a working solution concentration of working solution in each of the working solution reservoirs; and

a return system fluidly coupling each of the developer stations to one or more removable waste containers.

55. The system of claim 54 wherein the one or more removable waste containers comprise one or more compartments in each of the removable ink cartridges.

56. An ink replenishment system for delivering ink to a plurality of developer stations in an electrographic imaging device comprising:

a plurality of removable ink cartridges each containing liquid ink;

a source of liquid carrier;

a fluid handling system coupling the cartridges to the respective developer stations;

a controller for separately controlling the flow of ink from each ink cartridge and liquid carrier from the source of liquid carrier to working solution reservoirs, respectively, to maintain a working solution at a working solution concentration at each of the developer stations; and

a return system fluidly coupling each of the developer stations to one or more of the ink cartridges without the liquid ink.

57. An ink replenishment system for delivering ink to a plurality of developer stations in an electrographic imaging device comprising:

a plurality of removable ink cartridges each containing liquid ink;

a source of liquid carrier;

a fluid handling system coupling the cartridges to the respective developer stations;

a controller for separately controlling the flow of ink from each ink cartridge and liquid carrier from the source of liquid carrier to working solution reservoirs, respectively, to maintain a working solution at a working solution concentration at each of the developer stations;

a return system fluidly coupling each of the developer stations to one or more removable waste containers; and

staging tanks for temporarily retaining printed down ink before transferring it to respective removable waste containers.