Liquid container and method of manufacturing the same

Abstract

A method of manufacturing a liquid container having a tank chamber, first and second communication holes communicating with the tank chamber, and a flow channel communicating with the first communication hole, including welding a film to one surface of the liquid container in which openings communicating with the tank chamber and the flow channel, respectively, are formed; filing the tank chamber with a liquid from the second communication hole disposed in a vertical upper portion of the tank chamber; and delivering bubbles, which are gathered in the vertical upper portion of the tank chamber at a time of filling the tank chamber with the liquid, from the tank chamber to the flow channel through a bypass channel extending from an opening of the tank chamber to an opening of the flow channel through a non-welded portion of the film.

1 . A method of manufacturing a liquid container having a tank chamber, first and second communication holes communicating with the tank chamber, and a flow channel communicating with the first communication hole, the method comprising:
 welding a film to one surface of the liquid container in which openings communicating with the tank chamber and the flow channel, respectively, are formed;   filing the tank chamber with a liquid from the second communication hole disposed in a vertical upper portion of the tank chamber; and   delivering bubbles, which are gathered in the vertical upper portion of the tank chamber at a time of filling the tank chamber with the liquid, from the tank chamber to the flow channel through a bypass channel extending from an opening of the tank chamber to an opening of the flow channel through a non-welded portion of the film.   
     
     
         2 . The method according to  claim 1 , further comprising:
 welding the non-welded portion of the film to close the bypass channel after the tank chamber is filled with the liquid and the bubbles are removed.   
     
     
         3 . The method according to  claim 1 , wherein
 the first communication hole is disposed in the vertical upper portion of the tank chamber and the second communication hole is disposed in a vertical lower portion of the tank chamber, in a posture of the liquid container at a time of consuming the liquid, and   the tank chamber is filled with the liquid in a posture of the liquid container which is vertically reverse of the posture of the liquid container at the time of consuming the liquid.   
     
     
         4 . The method according to  claim 1 , wherein
 the liquid container includes: a main tank chamber, communicating with the liquid channel; and a liquid sensor, communicating with the second communication hole and operable to detect the liquid, and   the tank chamber is a bubble trapping chamber for preventing the bubbles from entering into the liquid sensor at the time of consuming the liquid.   
     
     
         5 . The method according to  claim 2 , wherein
 in the delivering of the bubbles, one or more protrusions protruding from one surface of the liquid container are used as the non-welded portion, and a gap formed between the one surface of the liquid container and the film by the one or more protrusions is used as the bypass channel, and   in the closing the bypass channel, the one or more protrusions are welded and pressed with the film.   
     
     
         6 . The method according to  claim 2 , wherein
 in the delivering of the bubbles, one or more grooves recessed at one surface of the liquid container are used as the non-welded portion, and a gap formed between one or more bottom of the one or more grooves and the one surface of the liquid container is used as the bypass channel, and   in the closing the bypass channel, the one or more grooves are welded with the film to close the one or more grooves.   
     
     
         7 . The method according to  claim 2 , further comprising:
 discharging the bubbles from the flow channel at the time of filling with the liquid.   
     
     
         8 . A method of manufacturing a liquid container, the liquid container comprising:
 a first liquid containing portion, communicating with air, and adapted to contain a liquid therein;   a second liquid containing portion, disposed downstream of the first liquid containing portion, and adapted to contain the liquid therein;   a liquid flow channel, communicating the first liquid containing portion with the second liquid containing portion;   a liquid sensor, disposed downstream of the second liquid containing portion, and operable to detect the liquid; and   a liquid supply section, disposed downstream of the liquid sensor, and adapted to discharge the liquid,   wherein the second liquid containing portion is arranged adjacent to the liquid flow channel,   a part of the second containing portion and a part of the liquid flow channel are formed by fixing a film to a housing,   the second liquid containing portion includes a first communication hole communicating with the liquid flow channel and a second communication hole communicating with the liquid sensor, and   the first communication hole is disposed at an upper side of the second liquid containing portion and the second communication hole is disposed at a lower side of the second liquid containing portion, in a posture of the liquid container at a time of consuming the liquid,   the method comprising:   a first process of forming the second liquid containing portion, the liquid flow channel and a bypass channel communicating the second liquid containing portion with the liquid flow channel, by fixing the film to the housing while keeping, unfixed, a part of a border between the second liquid containing portion and the liquid flow channel in a fixing surface of the housing to which the film is fixed;   a second process of filling the liquid container with the liquid from the liquid supply section; and   a third process of fixing the film to the part of the fixing surface to close the bypass channel.   
     
     
         9 . The method according to  claim 8 , wherein
 a protrusion or a groove is provided at the border of the fixing surface of the housing,   in the first process, the bypass channel is formed by fixing the film to the fixing surface while keeping the part of the fixing surface including the protrusion or the groove unfixed, and   in the third process, the film is fixed to the part of the fixing surface including the protrusion or the groove to close the bypass channel.   
     
     
         10 . The method according to  claim 8 , wherein
 the first communication hole is disposed proximal to the border between the second liquid containing portion and the liquid flow channel, and   the bypass channel is disposed at an upper side of the first communication hole in a posture of the liquid container at a time of filling with the liquid.   
     
     
         11 . The method according to  claim 8 , wherein
 the first communication hole and the second communication hole are arranged diagonal to each other.   
     
     
         12 . The method according to  claim 11 , wherein
 a part of the first liquid containing portion is formed by fixing the film to the housing.