Note: Descriptions are shown in the official language in which they were submitted.
1l l~eferences of Interest
-
lZ U. S. Patent 3,7877882, entitled "Servo Control of Ink
13 Jet Pump~, having Gary L. Fillmore, et al, as inventors.
14 U. S. Patent 3,831,728, entitled "Ink Jet Printing Apparatus
with Overrun of Printhead to Insure Better Visibility", having
16 Joe W. Woods and Krikor Yosmali, as inventors.
17 Article, "Capacitive Ink Level Detector", authored by
18 ~. W. Phillips, IBM Tecnnical Disclosure Bulletin, Vol. 16,
1~ No. lO, March, 1974, Pp. 3293 and 3294.
., .
~ackground of the Invention and Prior Art
21 The Woods, et al patent describes ink jet printing apparatus
22 that is fairly representative of a synchronous pressure jet
23 system. The present case makes use of the prlnciples set forth ~
24 in the Woods, et al case for printing purposes and further ~ ~:
25 enhances the Woods, et al apparatus by an efficient ink supply ;~
26 and recirculatin~ system. The Fillmore, et al patent describes :
27 a servo system that is useful in the p~esent system. The
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l I'IIillil~s article describes an ink level de-tector that is useful
2 in the I~resent c~se. No other art is known that is particularly
~ pertinent to the many features set forth in the present case. ~
4 Summary of the Invention ~ ~ -
_
As indicated in t}le Abstract, the present case concerns
G an ink recirculating system for ink jet printers making use
7 of a readily removable ink bottle (cartridge) serving as the ;
8 main source of ink in the system. This enables easy periodic
~ replacement of the bottle upon depletion. Typically, the
bottle, when positioned in its receptacle, serves as an integral
11 part of the ink recirculating system enabling control of various
12 conditions encountered during operation of the system such as `~
13 pressure differentials, and the like. The system further incor-
14 porates filtration and screen units, valves, air bubble catchers,
lS a single pump, a J-tube with a servo point, and an expansion
16 chaIll~er or reservoir primarily serving to accumulate excess ink .;
17 during operation.
18~ Objects
~9 A primary object of the present invention is to provide an
20 ~ ink recirculating system particularly useful in an ink jet
21 printer environment and operating with high reliability and
22 ~efficiency.
2~ Another object of the present invention is to provide a
24 system of this nature incorporating a removable ink bottle
serving as the primary ink supply source and enabling periodic
26 replenishment of the ink supply.
27 Still another object of the present invention is to provide ~ `
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l a syst~ oL tllis nature incorporating racilities for determining
2 ~hell tl~e ink supply nceds rcplenisllment.
3 Also, an object of the present invention is to provide
4 structures wherein the primary reliance is on vacuum principles,
rather tllan high pressure principles, thereby enabling more
6 suita~le place~ent of the components, such as the ink bottle,
7 for optimum performance.
8 Another o~ject of the present invention is to provide
9 compensating or accommodating structures in order to compensate
for or control pressure and vacuum differentials, temperature
11 variances, and the like.
12 A furtller object of the present invention is to provide
13 convenient servicing facilities for the system.
14 A still further object of the present invention is to
15 provide a system o~ this nature wherein all recirculating -;
16 requirements are met by a single pump.
17 The foregoing and other objects, features, and advantages
18 of the inven*ion will be apparent from the following mor~
~ .- .
19 particular description of the preferred embodiment of the inven~
tlon~as illustrated ln the accompanying drawings.
21 Drawings
. .
22 In the Drawings~
, . ~ . .
23 Fig. 1 illustrates an ink jet printing system incorporating
24 a prin*er and having an associated magnetic card recording/repro- ;~
ducing unit with both line printing and character-by-character
26 printing faciIities.
27 Fig. 2 illustrates structures in tlle ink jet printer head
28 assembly with an associated grating.
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~ . 3 illustriltcs scveral components of ink jet apparatus
2 inccrporating the ink recirculating system and including a ;~
3 power module, a print module, and document handling acilities.
4 Fig. 4 illustrates an ink bottle useful in the system of
Fig. 3.
6 Figs. 5a and 5b illustrate a needle used for penetrating
7 the ~ottle shown in Fig. 4.
8 Fig. 6 is a diagram of an ink recirculating system in 1~ ' .
9 accordance witll the present invention.
Fig. 7 shows a relief valve incorporated in bubble catcher
11 structures shown in Fig. 6. --~
12 Fig. 8 illustrates a suitable bellows pump that may be
13 used in the recirculating system of Fig. 6. ?1: :
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I I)~tailc~ L)cscrii)tLon
2 Ei~. l illustrates an ink jet printing system incorporating
3 a printer l with an associated magnetic card recording/repro-
4 ducin~ unit 2. Card unit 2 is shown for convenience only since
it is apparent that other kinds of storage units, recording/repro-
6 ducing units, magnetic tape units and the like, may be used in
7 the system. Printer l has the usual keyboard 3 which preferably
8 is of the electrical type. Printer 1 incorporates an ink jet
9 l-ead assembly 4 arranged for travelling movement from left to
rigllt ~and conversely) adjacent a document 7 to be printed in
11 order to print lines of information on the document. Assembly
12 4 has an ink drop nozzle and an associated grating 8 for drop ~ -
13 location purposes. Printer 1 may be provided with various
14 control buttons 10, 11, 12 and 13 for automatic, line, word,
and character printing, respectively. Other keybuttons 15-18
1~ concern mode selection, that is, record, playback, adjust, and
17 skip, respectively. Printer 1 incorporates a left margin reed
18 switch 30, a drop carrier return reed switch 31 and a right -
;, - .
19 margin reed switch 32.
20 The magnetic card unit 2 has a load slot 25 and a track , ;~
21 indicator 26. Also provided on unit 2 is a card eject button
22 27, a track stepdown button 28 and a track stepup button 29 for ~ ;
23 relocating the scanning transducer with respect to the various
24 tracks on the card.
Referring to Fig. 2, varlous structures incorporated in a
26 representative head assembly 4 are illustrated. This includes
27 a pump 40 for directing ink from an ink supply conduit 41 through
28 a crystal 42 and nozzle 43. Crystal 42 is energized, that is, `
29 pulsed at high frequencies ln order to produce drops. The rate
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l of iolpulsirlg crystal 42 may be in t?-e range of 100 kiloHertz
2 for example. Ink drops are emitted from no~zle 43 and pass
3 throug]l a charge electrode 44 for variable charging in accord- ~-
4 ance Wit}l the output of a charge amplifier to deflect the drops
in a column an amount representing the vertical height of the
6 drop location in any given character. As iliustrated, the
7 letter capital "S" designatecl S0 comprises a number of vertical
8 columns 51. The printing is such that a sequence of vertical
9 columns, each comprising a plurality of drops, such as 40 in
number, is propelled from nozzle 43 toward document 7 ~see
11 Fig. 1) for the printing of the character involved. If drops
12 are not required for printing, they are directed to a gutter 53 ~ -
13 for passage back to the ink supply, as will be subsequently
14 described. A pair of deflection plates 60 and 61 is positioned
in the path of travel of the drops leaving the charge electrode
16 44. A constant high potential is applied across plates 60 and
17 61 and this, in cooperation with the variable charge on the
18 individual drops, determines tlle amount of deflection as the
19 drops are directed toward document 7. Grating 8 in this i~
instance is shown as being positioned horizontally rather than
21 vertically as in Fig. 1, but the positioning is immaterial.
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1 ~nk Jet l'rinter Assembly
. . .
2 R~ferring to Fig. 3, certain details of an ink jet
3 printer like thc pr:inter of Fig. 1 are shown. It is noted that
4 a keyboard is not shown in Fig. 3. Typically, a printer o-f
this nature incorporates document handling facilities 70 having
6 a platen 71 for supporting a document to be printed. When in
7 use, the document handling facilities 70 are positioned in
8 proximity to the print module 73 and more especially the ink
9 jet head assembly 4 in order to print characters on document 7,
10 not shown in Fig. 3. Carrier 5 supports head assembly 4 for ~ ;
11 movement from left to right and conversely in order to print `~
12 information on the document mounted on platen 71, as previously .
13 descri~ed. Of particular interest in Fig. 3 is the ink bottle
l4 (cartridge) 100, further shown in detail in Figs. 4 and 6.`~
Bottlc 100 is mounted on power module 75 which includes a drive
16 motor 80 interconnected by various clutches and drive assemblies
17 81 through cables 82 and 83, for example, to drive carrier 5
18 back and -forth during printing. ~-
,.
19 Further associated with print module 73 are electronic ~
20 ~ modules 86 and 87. A filter, filter B, is also ilIustrated in ~;
21 Fig. 3.
22 Not all of the components of the ink recirculating system
23 according to tne present invention are shown in Fig. 3j but they
2~ are illustrated in other drawings, such as Fig. 6. As an ;
example, the supply and return lines between bottle 100 and
26 head assembly 4 are not shown in Fig. 3. Of particular interest
27 is that all of the components on the power module 75, Fig. 3,~
28 remain relatively stationary during printing operations. This ~ -`
29 contrasts witll other components associated with head assembly 4
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1 ~hicll are mounte~ for movement on print module 73. Greater
2 stability of the ink supply in bottle 100 is achieved by having
3 such separation of the components. This is further illustrated
4 in Fig. 6. Components above and to the right of line 200 move
during printing operations while those below and to the left of
6 line 200 remain relatively stationary.
7 Ink Bottle ~`
8 Fig. 4 illustrates bottle 100 in greater detail. It is
9 also shown in cross-section in Fig. 6. The bottle consists of
a blow-molded, polypropylene, cylindrical shell. Typical dimen-
11 sions are: height 4.1 inches and outside diameter 2.6 inches;
12 shell thickness approximately .045 inches. The bottle is -
13 stoppered with an RTV silicone rubber plug that has needle- ;
14 puncturable septums 90 and 91. The bottle is arranged for
alignment in a bottle receptacle 142, ~ig. 3, and has a pro-
16 jection 103 arranged for actuation of a cut-of valve 102, Fig.
l7 6. The capacity of the bottle is 6.9 ouncès of ink, however, `~
18 the fill volume is actually six ounces and only four of the six
-:
19 ounces àre actually used. Iwo ounces are discarded with the
20~ used bottle. Bottle 100 is equipped, near the base, with two
, ~
21 embossed copper adhesive tape plates 105 and 106, which inter-
22 face with a level detect circuit using capacitive electrical
23 principles to detect the ink level within the bottle. Reference
24 is made to the Phillips article.
The full bottle, being sealed, has the capability of
26 developing internal pressure when heated or exposed to an
27 alllbient pressure lower than the ambient pressure at the time of
28 r~ lg. The iowest fill pressure for a rigid bottle to still
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I retain zcro prcssure differclltial on tlle plug at 7850 feet of
2 clcvatio~ ovc ~ea level an~ 1L~OOI~ is 6.5 pounds per square
3 inch al~solute (psia). However, since the deflection of the
stopper makes the bottle less than rigid, the fill pressure
needed to accommodate the pressure increase and still retain
zero pressure differential across the plug is 9.8 psia. The
7 bottles are filled at 9.0 psia. Another benefit is derived
8 from the reduce~ bottle pressure in that when frozen at -40F,
9 no rupture or distortion of the bottle results. The bottle has
10 been -frozen upright, inverted, and on its side with no adverse -
11 reactions to the shell, plug or assembly. The ink expansion
12 is amply contained.
13 When the ink bottle 100 has been depleted to two ounces
14 of residual ink and is ready to be replaced with a new bottle,
lS it is important not to allow any air to get into the ink system
16 while removing the bottle, especially air in the pump inlet, or `~
17 supply line. This is accomplished by cutoff valve 102 which ~ ;
18 closes the inlet line 104b upon removal of bottle 100. ~ ;
~19 ~ As indicated, about four ounces of ink are used from each
ink bottle 100. Typically, this represents four million
21 characters of printing and an expected use of perhaps twenty
22 bottles per year in the ink jet printer.
23 ~ Figs. Sa and Sb illustrate one of the needles, such as
24 needle 110 for example. Fach ne~edle comprises a sharp tip,
such as tip llOa, for easy penetration of the septum. Circula~
26 tlon of ink through the needle is by means of a cross-drllled
27 aperture llOb connected to a passage llOc
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1 Structural Cllaracteristics of Ink Recirculating System ~-.
2 The ink recirculating system, Fig. 6, consists of bottle
3 100 mounted on power module 75 and connected by hoses 104a-g to
4 pump 116 and nozzle 125 that are mounted on carrier S. This
is the input side oE the system and further includes bubble
6 catchers 120 and 122, capillary tube 1519 main valve 154 and
7 filters A~ B, and C. The return side of the system includes ~ -
8 gutter 53, J-tube 115, hoses 113a and 113b and screen element
9 117.
Circulation is as follows. Ink 116 from bottle 100 is
11 clrawn through needle 111, hoses 104a and 104b, filter A in
12 bubble catcher 120~ through hose 104c into another bubble
13 catcller 1~2 and then by hose 104d to pump 116 which provides
14 pre~ssure to the nozzle 125. Ink then passes through hose 104e,
15 capillary tube 151, hose 104f, filter B, and hose 104g to main
16 valve 154 which is turned on and off to control flow. There-
17 after ink goes from valve 154 by conduit 155, filter C, and
18~ conduit 156 to nozzle 125. The function of main valve 154 is
~19~ to preven~ ink from dribbling out of nozzle 125 and contamina~
; zo ~tinè~other machine elements. Ink from the nozzle which is not
Z~i used ln printing~is directed into~gutter 53 where it gravity `
~f1ows~downward at 126 to elbow 11~5a~of J-tube 115. From t]lis
23 point the ink is drawn into bottle~100 through hose ll3a,
24 ~screen 117 and hose 113b, needle llO and standpipe 128 which
extends on the inslde almost to the top of bottle 100. Screen
26 117 is provided between hoses 113a and 113b for additional
27 filtration and strains out relatlvely large particles thus
28 insuring that there are no contaminants in the return llne to
29 bottle 100. Screen 117 is typically a flat stainless steel
plate in the range of oOl inch with apertures of comparable
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I size drillecl ~hrough it.
2 Tlle ink is clrawn into the return line by the vacuum created
~ when the ink is drawn out of the bottle by the pump 116.
4 When the amoun~ of ink removed :from the bottle exceeds the
amount directed into gutter 533 the ink level in elbow 115a
6 will go down allowing a bubble of air to enter hose 113b, thus
7 compensating for the ink used in printing. During constant
8 tcmperature operation, the ink level will automatically servo :
9 about the elbow, only allowing enough air to enter the system
to compensate :Eor the ink used in printing. A reservoir 133
~1 is interconnected to J-tube 115 by two small openings 134 and
12 135, one at the top and one at the bottom of the reservoir.
13 Reservoir 133 provides a place for ink to accumulate if temper- :
14 ature expansion of air in bottle 100 is at the same rate as ink
15 removal from the bottle. In this case, no suction is created :~;
IG in the bottle to draw the returning ink into the bottle and it
17 will accumulate in the J-tube 115 and reservoir 133. Reservoir
;;I8 ~133 1S sized such that i~ will accommodate the largest amounts
19 of ink~possible over the tempera~ure range expected. The reser-;
;~volr ls filled with~a material 140,~ such as open-cell foam, ~o
21 ~prevent sloshing of ink durlng movement of carrier 5. As
22 indicated, bottle 100 moves~into a receptacle 142 shown in-Fig.
23 3, which guides the bottle on and off of needles 110 and 111.
24 Other structural characteristics of interest are~as
follows. Filter A may be formed of woven stainless steel
26 pleated mesh. It's purpose is to clean out small particles .! ~:
27 that might stop up pump 116 and filter A is designed to last
?8 the life of the machine. Filter B simply provides further
29 filtratlon following pump 116. Filter C is positioned
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l in close proximity to nozzle 125 to prcvent nozzle clogging.
2 Ordinarily, contaminants are held on the various filters
3 during the life of the machine.
4 Bubble catcher 120 serves to keep filter A from becoming
air-locked. As ink is pulled from bottle 100, the pressure
6 differentials form minute air bubbles in the stream which will
7 tend to accumulate on the left side of filter A, Fig. 6, and
8 block flow of the stream. To prevent this, the upper portion
9 120a of bubble catcher 120 is provided. Thus, bubbles 121
are able to rise in the ink and accumulate in the upper section
11 of portion 120a. A similar function is performed by bubble ;
12 catcher 122. Bubble catchers 120 and 122 are provided with
13 valves 160 and 161, respectively, that enable periodic servicing
14 of the bubble catchers by relief of the air bubbles trapped in - ;
15 the bubble catchers. A typical air valve for this purpose is -~
16 illustrated in Fig. 7 as comprising a valve seat 165 against
17 which the valve disk 166 and resilient element 168 are spring
~18 loaded by means of spring 167. Connection of a hose on port r~
19 170 and establishment of a vacuum during servicing procedures
~Z overcomes tension of spring 167, enabling valve disk 166 and
2~1 element 168 to move to the right in Fig. 7 and release air from ~ :
22 the bubble catcher.
23 Considering cutoff valve 102, this valve is provided
.
24 between bottle 100 and filter ~A to compensate for conditions
established in bubble catcher 120, hose 104b, bubble catcher
26 122, and pump 116. This lS provided since the air in the top
27 of bubble catcher 120, for example, is at a vacuum about the
:
28 same level as in the pump supply line 114. In the absence of ~ ~
29 a cutoff valve 102, the vacuum in bubble catcher 120 would be ` ~-
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I relievcd by air being drawn into needle lll upon removal of
2 bottle lO0 from receptacle 142. The next time a bottle lO0
3 were to be removed, tile air volume present in bubble catcher 120
4 would be even bigger ~han the previous time, this being a cumu-
lative process that becomes more pronounced upon each bottle
6 replacement. To avoid this, cutof valve 102 prevents air from ~`
7 going into line 104b~ Valve 102 effectively closes before
~ needles 110 and 111 are removed from bottle 100. When a fresh
9 bottle lO0 is reinserted, needle~ 110 and 111 enter the bottle
and then cutoff valve 102 opens.
ll Considering pump 116, the details of its construction are
12 illustrated in Fig. 8. Any suitable pump can serve the intended
13 function but in this case the pump is a bellows pump. Referring
14 to Fig. 8, ink enters through hose 104d and is discharged - ~
through hose 104e. The pump assembly includes flapper valves ~ -
16 180 and 181, a pump bellows 182, a return spring 183 and a
17 solenoid portion 184, all suitably mounted together in support
18 members 186-190.
19 ~ Considering main valve 154, Fig. 6, this valve is provided -
to avold dribbling of ink following shutdown and during startup. ,-~
21 Associated with main valve 154 is a by-pass member 162 having
22 an air vent 163. By-pass member 162 connects main valve 154 to
23 reservoir 133. This connection to air vent 163 is provided since
24 in some cases when ink accumulates high enough in J-tbe 115,
. -:
thus fllling reservoir 133, top opening 134 could acquire a film
2~ of ink, disturbing the pressure conditions. In some cases not
27 enough positive pressure could be created sufficlent to break `
2g through the ink film over opening 134, thus allowing ink in
29 .J-tube 115 to accumulate higher than normal and to slosh out of
gutter 53, and causing a malfunction. Provision of air vent
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I l63 erla~les air to l~ass out of vent l63 or J-tube l15,
2 whichever proves to be more convenient under the conditions at
3 the moment.
4 Operation
A representative operation of the system is as follows.
6 Bottle 100 is shoved onto needles 110 and 111. The initial
7 vacuum in bottle 100 draws ink dry from gutter 53 and by way of
8 ~ es 113a and 113b through screen 117. This also pulls air
9 throug]l the return line in most cases which will result in ~
10 atmospheric pressure being established in bottle 100. ; ;
11 Subsequently, pump 116 begins operation and valve 154
12 opcns. At this point, no vacuum exists in the return lines
13 comprising lines 113a and 113b. However, vacuum will be
l4~ established when ink falls in gutter 53 to the bottom portion
of J-tube 115 and fills up to the servo point 115b of J-tube
16 115. Wllen this occurs, no further air can reach bottle 100
17 and vacuum condi~ions are initiated in bottle 100. Vacuum
18 continues~to~build~up in bottle 100 and in about 30 seconds
19 from turn-on time, the flow of ink in the return lines 113a and
113b and ln the pump lines 104a - 104d will reach approximate
21 equilibrium. Also, ink in the J-tube will tend to back-up and
.
22 ~ flow into reservoir 133 during this 30 second period. Such ~`
23 conditions and ink~levels are maintained until printing begins.
24 As ink flows during printing to gutter 53, it falls
.
25 toward servo point 115b. If pump 116 draws more ink from ~;;
26 bottle I00 than there is flowing into the return line, then
27 the ink level at servo point ll5b will drop and air will pass
28 through to ink bottle 100. This will tend to relieve the
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vacuum slig}ltly in bottle 100, thereby slowing the flow rate
2 back to bottle l00 and allcwing the level at servo point 115b
3 to rise back up again. Thus, servo point 115b is the only
4 point at which air is permitted to return to bottle 100.
In the overall structural configuration~ it is mandatory
6 that servo point 115b be located lower than reservoir 133. To ~-
7 enal)le gravity flow of ink to the servo point, it is necessary
8 that an air vent be maintained to the servo point 115b location
9 by keeping the J-tube 115 and gutter 53 unobstructed. ;~
The aforementioned conditions prevail throughout operation
11 until pump 116 is turned off near the end of printing. It is
12 noted that ink is pumped continuously from turn-on to turn-off
l3 of valve 154. After valve 154 turns off, ink continues to flow
14 in the gutter return lines 113a and 113b. This occurs due to `~
the vacuum created ln bottle 100 which tends to pull ink on
16 througll the return line until equilibrium is reached.
. ~ . .
17 One consideration in the system that needs to be taken into
18 account is the fact that the relationships are such that the `~
19 top of return needle 110 should be maintained higher than the
~. .
highest point of ink expected to exlst in J-tube 115 or reser-
21 volr 133 in order to avoid ink spilling out of the system in
22 the event of removal of bottle 100. To fully prevent this, an
23 optional cut-off valve 192 may be provided. If this is done
24 the height of needle 110 is unimportant.
1~ point of interest is that the vacuum in bottle 100
26~ mainly depends upon the differential between standpipe 128 in
27 bottle 100 and servo point 115b which, in a typical case may
28 be 4.0 inches of mercury and the pressure drop in the return ~ ~
29 lines 113a and 113b. In any case, the operating vacuum ~ !
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1 in ~ottlc 100 is somewhat less than 20.0 inches of mercury.
2 Another point of interest is that as ink is consumed
3 from bottle 100, tlle concentration tends to increase due to
4 its having been in contact with the air from nozzle 125 to
gutter 53 and with the air in J-tube 115 and in reservoir 133,
6 for example. As concentration increases, viscosity tends to
7 increase and pump 116 is no longer able to maintain the custom-
8 ary pressures required to allow the ink to break up into drops
9 for printing or return to gutter 53. A suitable servo system,
such as that described in the Fillmore, et al patent, may be
~1 provided to increase pump pressure as these conditions occur
12 in order to maintain pump drive at a suitable level during
13 operation.
~4 Disposing o:E the ink bottle when the level of ink reaches
about 2 oz. avoids difficulties due to the ink becoming overly
16 concentrated.
17 As a modification, it may be desirable to incorporate
18 additional filtration structures in bottle 100 itself. In this
19 ~ ~case, throwing bottle 100 away disposes of the contaminants
caught by~the bottle filter, as well.
21 The~foregoing arrangements establish a highly efficient ;
22 system for supplying ink to an ink jet printer apparatus~
Z3~ ~ While the invention has been particularly shown and
24 described with reference to a preferred embodiment, it will be
understood by those skilled in the art that various changes
26 in form and detail may be made without departing from the
27 spirit and scope of the invention.
28 What is claimed is:
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