Convertible printer

A convertible printer usable with either a flexible media or rigid media is disclosed.

BACKGROUND

In this information age, printers have become a nearly indispensable part of life. With these developments, printing has moved well beyond the traditional use of paper as a print media, as printing now extends to many other types of media, such as wood, metal, foam, and many other types of rigid materials. Moreover, numerous types of inks and/or toner are used to achieve different effects on a particular type of media.

Some inks, such as solvent inks, work best upon application of some form of heat while some other inks, such as ultraviolet-curable inks, typically do not require heating. In addition, a preferred heating or drying mechanism suitable for use with solvent inks and/or flexible media may not be helpful when printing on a rigid media and/or when using other inks, such as the ultraviolet-curable inks. In fact, because high quality printing is very dependent upon the type of media, the type of ink, and how the ink is dried or cured, a quite diverse range of printers exists. Accordingly, a conventional printer typically uses just one type of ink, such as a solvent ink. Likewise, in this environment, a conventional printer also would typically use just one type of media, such as a rigid media, while a different conventional printer would employ a different type of media, such as a flexible media arranged in a roll-to-roll configuration.

The significant differences between the many different types of inks and the many different types of media, as well as the different sizes and shapes of media, can result in a business owning many different types of printers—with each different printer dedicated for a different purpose. This seeming duplicity frequently raises maintenance costs, increases training time, increases ink costs, and occupies a lot of space, among other challenges. Accordingly, most businesses and consumers face a daunting task of choosing the right combination of printers and associated equipment to meet their goals.

DETAILED DESCRIPTION

Embodiments of the present disclosure provide a convertible, hybrid printer that allows printing with either a flexible media or rigid media. The convertible, hybrid printer includes one or more selectively activatable heating mechanism on opposite sides of a print-heat zone so that the appropriate type of heating is always available, regardless of whether the flexible media or the printed media is being printed upon. Moreover, the convertible, hybrid printer allows repositioning of a vertical spacing between the print-heat assembly and a media assembly to accommodate the different thicknesses of the respective flexible and rigid types of media.

These embodiments, and additional embodiments, are described in association withFIGS. 1-6.

As illustrated inFIG. 1, in accordance with one embodiment of the present disclosure, a printing system10includes a printer12, which is convertible between a first configuration20and a second configuration30. As shown inFIG. 1, printer12includes a print-heat assembly40and a media assembly50. The print-heat assembly40includes a frame42which supports a print station44, a first heater46, and a post heater48. In one aspect, the print station44includes a printhead array45configured to eject ink onto a media such as media web70. The print-heat assembly40also includes, or is in communication with, an ink supply49to supply ink to printhead array45of the print station44. In one embodiment, the first heater46and/or the post heater48comprise a radiant heater, convective heater, combinations thereof, or another non-contact heating mechanism, as known in the art. In one aspect, a post heater48generates and directs a substantially higher temperature heat than the first heater46. In another aspect, first heater46and post heater48are positioned to face a printing side of media web70and hence, are sometimes herein referred to as print-side heaters.

In one aspect, frame42is configured to maintain the print station44, the first heater46, and the post heater48in a fixed relationship to one another in both the vertical orientation (as represented by directional arrow B) and the horizontal orientation (as represented by directional arrow A). In one aspect, because printing station44, first heater46, and post heater48extend along the same general horizontal orientation, each of these respective components are all aligned to act on a portion of media web70that extends in a single generally horizontal plane (i.e. a plane that is generally parallel to the generally horizontal orientation through which printing station44, first heater46, and post heater48extend) within the print-heat zone.

The media assembly50comprises a roller system60that includes at least rollers62and64and which is configured to provide rolling support for the media web70. As shown inFIG. 1, media web70includes directional arrows for illustrative purposes to indicate the direction of travel of media web70. In one aspect, the media assembly50also includes an intermediate support66configured to further support media web70between rollers62and64. In one aspect, intermediate support66is positioned on a non-printing side of media web70, i.e. on a side of media web70that is opposite the printing side of media web70where first heater46and post heater48are located.

As further illustrated inFIG. 1, in the first configuration20, printhead array45of station44is vertically spaced above media web70by a distance of H1while first heater46is vertically spaced above media web70by a distance of H2(with the position of media web70being measured at a top portion of roller62or at a top portion82of intermediate support66). The post heater48is vertically spaced above media web70by a distance of H3(via measuring the position of media web70at a top portion of roller64or at the top portion82of intermediate support66). As previously mentioned, frame42maintains the fixed relative vertical spacing between print station44, first heater46and post heater48.

In the first configuration20, both first heater46and post heater48are activated. Accordingly, as the media web70travels through the print-heat zone (established by print-heat assembly40), print station44ejects ink onto the media web70with the first heater46and post heater48subsequently heating the printed ink on media web70.

Printhead array45comprises a plurality of drop-on-demand fluid ejection devices. In one embodiment, the fluid ejection devices comprise thermal inkjet print heads while in other embodiments, the fluid ejection devices comprise piezoelectric printheads or other printheads known in the art.

In some embodiments, ink supply49includes a low-solvent ink or an aqueous ink that includes at least a pigment and a latex component, as well as water and/or minimal solvents. Once ejected onto media web70, the water and/or minimal solvents are effectively removed through evaporation while the latex and pigment remains on media web70. As the printed ink on the web70passes by first heater46and post heater48, the latex is heated to a temperature sufficient to form a film over the pigment, thereby securing the latex-pigment mix to the media web70.

A second configuration30of printer12is provided to accommodate other types of media, such as rigid media92that is not provided in a roll-to roll configuration. In the second configuration30, print-heat assembly40and media assembly50include at least substantially the same features and attributes as print-heat assembly40and media assembly50in the first configuration20. However, in the second configuration30, media assembly50also includes additional features and attributes as described herein. In particular, media assembly50additionally includes a rigid media support mechanism91including a media carrier90configured to releasably retain the rigid media92thereon. In one aspect, the rigid media92includes a print side95A and a non-print side95B.

Furthermore, to accommodate the introduction of the rigid media support mechanism91, print-heat assembly40is raised to a more elevated position, as can be recognized by the increased vertical spacing between the print station44and media web70(as measured at roller62or at top portion82of support66, as previously described). This increased vertical spacing is generally represented by the difference between the vertical spacing between printhead array45and a top portion of roller62in the first configuration20(as represented by H1) and the greater vertical spacing between printhead45and a top portion of roller62in a second configuration30(as represented by H4). This increased vertical spacing is primarily used to accommodate a combined thickness of the media carrier90and rigid media92(as represented by indicator H8), which is substantially greater than the relatively negligible thickness of media web70.

It is also understood that the print-heat assembly40is movable along a generally continuous range of vertical positions above the media assembly50. Accordingly, when system10is deployed in the second configuration30, the print-heat assembly40is not limited to a single vertically spaced position, but rather the print-heat assembly40is configured for variable vertical positioning above the rigid media92and media carrier90. Moreover, when system10is deployed in the first configuration20, the print-heat assembly40is also configured for variable vertical positioning above the flexible media web70. Accordingly, the print-heat assembly40is configured to be moved into a first range of vertically spaced positions to accommodate different thicknesses of a flexible media and a second range of positions to accommodate different thicknesses of a rigid media. In one non-limiting example, in addition to accommodating the thickness of media carrier90, the variable vertical position of the print-heat assembly40can accommodate a relatively thick rigid media92(e.g., 50 to 100 mm) or a relatively thin rigid media92(e.g., 1 to 2 mm).

In another aspect, as illustrated byFIG. 1, printhead array45is separated from media92by a vertical spacing, represented by H5, while first heater46is separated from media92by a vertical spacing, represented by H6. Post heater48is separated from media92by a vertical spacing, as represented by H7. In one embodiment, the distance H1is substantially equal to the distance H5, while the distance H2is substantially equal to the distance H6, and the distance H3is substantially equal to the distance H7. However, in other embodiments of the distances H1, H3, H3are not substantially equal to the distances H5, H6, H7, respectively, as an operator may choose to have a different print-to-media spacing for each of the different types of media.

In one embodiment, in the second configuration30, because of the relatively large thickness of rigid media92(as compared to the negligible thickness of the flexible media web70) heat is applied to both the print-side95A and the non-print side95B of rigid media92. Accordingly, in this arrangement, the first heater46heats the ink that has been printed onto rigid media92, causing the ink to bond onto the rigid media92. When the ink is a low-solvent ink, such as the earlier described latex-pigment type ink, the first heater46causes melting of the latex component of the latex-pigment ink to bond the both the pigment and the latex to the rigid media92. In addition, post heater48is available to provide additional heating or drying of the printed ink on the rigid media92.

In some embodiments, media carrier90comprises additional features for ensuring high-quality printing of ink on the media web70. For example, in one embodiment, as illustrated inFIG. 1, media carrier90comprises a heating mechanism93. In one aspect, as the contact member190is heated (via an electrical source or a heat source that is not shown), the contact member190conductively heats the non-print side95B of rigid media92. Because first heater46is heating print-side95A of rigid media92, this heating action applied via heating mechanism93minimizes the temperature differential that would otherwise occur between the print-side95A and the non-print side95of rigid media92(due to the relatively large thickness of rigid media92). Accordingly, first heater46causes bonding of the latex-pigment ink on the print-side95A of rigid media92while the heating mechanism93of media carrier90prevents bending of the rigid media92that would otherwise occur due to a different thermal expansion on the print-side95A and non-print side95B of rigid media92(in the absence of the heating mechanism93).

In another aspect, in the second configuration30, rigid media support mechanism91is configured to move media carrier90in a back-and-forth path (as represented by directional arrow C) under the print-heat assembly40so that different patterns of ink are printed onto the rigid media92in successive passes of the media carrier90underneath the print-heat assembly40. Accordingly, in some embodiments, the heating mechanism93further includes a retaining mechanism to ensure stable positioning of rigid media92during movement of media carrier90. In some embodiments, this retaining mechanism is incorporated within a top portion of media carrier90as an array of vacuum ports194that are in fluid communication with a negative pressure source196, as illustrated in the partial, sectional view ofFIG. 2. With this in mind, by the application of a vacuum force through ports194, this retaining mechanism releasably, securely retains rigid media92on media carrier90. However, it is understood that in other embodiments, instead of a vacuum-based retaining mechanism. Rigid media support mechanism91and media carrier90comprise other types of retaining mechanisms, such as mechanical clasps, friction-based holders, pressure sensitive adhesives and the like.

Additional features and attributes of the second configuration30, including the rigid media support mechanism91, will be later described in more detail in association withFIG. 5-6.

Accordingly, as illustrated inFIG. 1, printer12is convertible between use with a flexible media in the first configuration20and use with a rigid media in the second configuration30. Because frame42of the print-heat assembly40maintains first heater46and post heater48in a fixed vertical relationship relative to print station44, a vertical adjustment of the print station44to accommodate a different thickness media (whether a flexible media or a rigid media on a media carrier) will automatically reposition the respective first heater46and the post heater48by a corresponding vertical adjustment. Moreover, because printer12includes both the first heater46(which is a print-side heater) and heatable media carrier90(which is a non-print side heater), printer12acts as a hybrid printer that can be used to print both a flexible media70or a rigid media92. These different types of media can be readily accommodated by printer12via adjusting the vertical spacing of the print-heat assembly40to accommodate the generally thicker rigid media92(and its rigid support mechanism91) or to accommodate the generally thinner flexible media70. It is also understood that this vertical spacing (i.e., a pen-to-paper spacing) is continuously adjustable within a range such that the print-heat assembly40is not strictly limited to a single rigid media position or a single flexible media position. Moreover, because the first heater46and the heatable media carrier are positioned on opposite sides of media web70, the appropriate combination of heating mechanisms are available, regardless of whether printing occurs on a flexible media or on a rigid media.

In another embodiment, printer12can be used in the second configuration30to print on a non-rigid media or flexible media that has a thickness comparable to the rigid media92.

FIG. 3is a flow diagram of a method150of printing, according to an embodiment of the present disclosure. In one embodiment, method150employs a printer having substantially the same features and attributes as the convertible printer12, previously described in association withFIGS. 1-2. As shown inFIG. 3, at decision box152, method150queries whether the media (to be printed upon) is a rigid material. If the query is answered affirmatively (i.e. yes), then method150initiates protocol156at box180in which a print-heat assembly, such as print-heat assembly40, is moved to a second range of positions that allowing greater vertical spacing below a print station to accommodate the thickness of the media carrier90and the generally thicker rigid media (as compared to a nominal thickness of a flexible media). In addition, as shown at box182, rigid media92is loaded onto the media carrier90for introduction into the print-heat zone. In protocol156, both a non-print side heater and the print-side heaters (such as first heater46and a post heater48) are activated as indicated at box184. In one aspect, the non-print side heater is provided via the heating mechanism93of media carrier90. The protocol156also includes moving the rigid media, via the heatable media carrier90, through the print-heat zone to print ink onto the rigid media, as shown at box186.

However, if the query at decision box152is answered negatively (i.e. no, the material is not rigid but is a flexible or non-rigid material), then method150initiates protocol154at box160in which a print-heat assembly, such as print-heat assembly40, is moved to a first range of positions to achieve less vertical spacing below a print station to accommodate an absence of media carrier90and a generally thinner flexible media (as compared to the generally greater, typical thickness of the rigid media92). In addition, as shown at box162, the print-side heaters (such as first heater46and post heater48) are activated as indicated at box164. The protocol154continues with loading of the flexible media onto a roll-to roll mechanism, whereby a non-rigid media or flexible media is advanced through the print-heat zone for printing of ink onto the flexible media. Because the media carrier90is not employed in protocol154, the non-print side heater (such as heating mechanism93of media carrier90) is not used to heat the flexible media in protocol154.

In one embodiment, the protocol154of method150illustrated inFIG. 3substantially corresponds to use of printer12in the first configuration20, as illustrated inFIG. 1. In another embodiment, the protocol156of method150illustrated inFIG. 3substantially corresponds to using printer12in its second configuration30, as illustrated inFIG. 1.

It is also understood that the various functions within each protocol154,156may be performed in a different order than that shown inFIG. 3and that some functions illustrated and described in association withFIG. 3can be performed simultaneously.

FIG. 4is a side plan view of a convertible, hybrid printing system300, according to one embodiment of the present disclosure. InFIG. 4, printing system300is shown in a first configuration302while the same printing system300is shown inFIGS. 5-6in its second configuration350. As shown inFIG. 4, a print-heat assembly240and a media assembly250each include at least substantially the same features and attributes of print-heat assembly40and media assembly50, respectively, as previously described in association withFIGS. 1-2. With this in mind, like reference numerals inFIG. 4(e.g. print-heat assembly240) describe like components inFIG. 1(e.g. print-heat assembly40). Accordingly, print-heat assembly240includes a movable frame242that supports a print station (indicated generally by244), first heater246, post heater248, and other components.

As illustrated inFIG. 4, frame242includes beams214and216which are spaced apart from each other along a horizontal orientation (as represented by directional arrow A) and along a vertical orientation (as represented by directional arrow B). In general, beams214,216are illustrated in an end view inFIG. 4, but can be best seen in a perspective view inFIG. 6. As shown inFIG. 6, beams214,216have a length that extends generally transverse to the travel direction of media web70. Accordingly, beams214,216support frame242(including print station244, first heater246, and post heater248) to extend across media web70, generally transverse to the travel direction of media web70. The beams214,216are connected together by one or more cross-support members218which form end pieces of frame242, as further illustrated inFIG. 6.

In one aspect, as further illustrated inFIG. 4, frame242further includes support member(s)220which extend generally inward and downward from beam216to thereby position first heater246over media assembly250in the print-heat zone. In this arrangement, first heater246is located along the path of the media web270, being interposed between print station244and post heater248. Moreover, while the print station244is positioned to be in close proximity to the media web270adjacent roller262, first heater246is substantially spaced apart from media web270and positioned generally across from beam217of media assembly250.

In one aspect, frame242also defines a top portion247and a bottom portion249with bottom portion249being vertically spaced above media web270.

Media assembly250includes rollers262,264which support media web270as media web270passes through a print-heat zone defined by the print station244, first heater246and post heater248. In one aspect, rollers213provide a media supply and a media rewind. Media assembly250also comprises a beam217that extends transversely to the direction of travel of media web270. In one embodiment, beam217further defines an intermediate support266, which includes a top portion382for further supporting media web270in the print-heat zone.

In one embodiment, media assembly250additionally comprises a frame272(e.g. a table) that generally supports media assembly250in a vertical orientation and which also supports print-heat assembly240vertically above media assembly250via a pair of actuator mechanisms375A,375B, which are schematically illustrated inFIG. 4. In one embodiment, actuator mechanism375A,375B is disposed at ends243of print-heat assembly240with ends243illustrated inFIG. 6. However, for illustrative purposes, actuator mechanism375A,375B is shown inFIG. 4as being located on opposite sides245of frame242. In either case, it is understood that the actuator mechanism375A,375B is positioned so as to not interfere with the advancement of media web70or other primary functioning of the print-heat assembly40.

Regardless of whether it is positioned on the sides or the ends of print-heat assembly40, the actuator mechanism375A,375B is positioned and configured to cause selective vertical positioning of the print-heat assembly240relative to media assembly250. With this arrangement, the printing system300can be converted between the first configuration302(shown inFIG. 4) and the second configuration350, shown inFIGS. 5-6. In one aspect, the actuator mechanism375A,375B comprises one or more hydraulic lift mechanisms or other mechanisms known in the art for providing selective vertical positioning.

Controller278comprises one or more processing units and associated memories configured to generate control signals directing the operation of printing system300, including print-heat assembly240and media assembly250. In addition, in response to or based upon commands received via a user input or instructions contained in the memory of controller278, controller278also generates control signals directing operation of actuator mechanism375A,375B to selectively control the vertical position of print-heat assembly240relative to media assembly250. In this way, printing system300is converted between use in the first configuration302(shown inFIG. 4) to accommodate a flexible media and the second configuration350(shown inFIGS. 5-6) to accommodate a rigid media.

For purposes of this application, the term “processing unit” shall mean a presently developed or future developed processing unit that executes sequences of instructions contained in a memory. Execution of the sequences of instructions causes the processing unit to perform steps such as generating control signals. The instructions may be loaded in a random access memory (RAM) for execution by the processing unit from a read only memory (ROM), a mass storage device, or some other persistent storage. In other embodiments, hard wired circuitry may be used in place of or in combination with software instructions to implement the functions described. For example, controller50may be embodied as part of one or more application-specific integrated circuits (ASICs). Unless otherwise specifically noted, the controller is not limited to any specific combination of hardware circuitry and software, nor limited to any particular source for the instructions executed by the processing unit.

Accordingly, with this arrangement shown inFIG. 4, in its first configuration302printing system300operates in substantially the same manner as printer12when in its first configuration20, as previously described in association withFIGS. 12.

Referring again toFIGS. 5-6, in one embodiment, printing system300is positionable into its second configuration350and in this second configuration350, additionally comprises first lateral support mechanism280and second lateral support mechanism310. In one embodiment, first lateral support mechanism280comprises a table281including legs283, a tabletop285, and an array284of rollers287extending across the table top285. As illustrated inFIG. 5, the table281is arranged and positioned to be immediately adjacent a first side320of media assembly250to be located near roller262and print station244of print-heat assembly240.

In one embodiment, second lateral support mechanism310includes a table301including legs303, a tabletop305, and the previously described, rigid media support mechanism291. The rigid media support mechanism291includes a media carrier290that is slidably movable relative to tabletop305of the second lateral support mechanism310and which is configured to receive and releasably retain rigid media292. In another aspect, media carrier290includes a heating mechanism293that is configured to provide contact heating of the non-print side295B of rigid media292during heating from first heater246to thereby maintain a generally uniform temperature gradient between the print side295A and the non-print side295B of rigid media (which thereby prevents unwanted bending of media292).

In one embodiment, heating mechanism293of media carrier290comprises substantially the same features and attributes as heating mechanism93(as previously described in association withFIGS. 1-2). Accordingly, with this arrangement, media carrier290is configured to releasably retain and heat the non-print side295B of rigid media292as media carrier290travels back-and-forth (as represented by directional arrow C) relative to media support assembly250and over tabletop305of the second lateral support mechanism302.

In one embodiment, a control mechanism306extends from, and is in communication with, rigid media support mechanism291to control slidable movement of media carrier290and the vacuum applied to media carrier290. In another aspect, control mechanism306provides control over, and electrical communication with, heating mechanism293of media carrier290. In one aspect, control mechanism306is in communication with controller278to coordinate control of media carrier290with the other functions of print-heat assembly240and media assembly250.

As further illustrated byFIGS. 5-6, second lateral support mechanism310is positioned and arranged to be immediately adjacent second side322of media assembly250so that media carrier290of the rigid media support mechanism291is positioned for movement through the print-heat zone between print-heat assembly240and media assembly250.

With the first lateral support mechanism280positioned on first side320of media assembly250and the second lateral support mechanism310positioned on the second side322of media assembly250, movement of media carrier290of rigid media support mechanism291(as represented by directional arrow C) is fully supported on either side of media assembly250. For example, when the rigid media support mechanism291advances media carrier290to extend outwardly beyond first side320of media assembly250, rollers287of first lateral support mechanism280provide rolling support for media carrier290of rigid media support mechanism291. With this arrangement, a smooth controlled motion of rigid media292is maintained during printing of ink from printhead array245of print station244onto rigid media292.

In one aspect, in a manner substantially similar to that previously described for printer12in connection withFIG. 1, when the second configuration350of printer300is adapted to accommodate rigid media292, heating mechanism293of media carrier290acts to heat a non-printing side of rigid media292. As in the first configuration302, both the first heater246and post heater248located on the printing side of media web272are activated to direct heat (as schematically indicated by directional arrow H inFIG. 4) onto the print-side of rigid media292(and the printed ink thereon).

It is also understood that in the second configuration350and with the introduction of media carrier290(and the rigid media292thereon) between print-heat assembly240and media assembly250, printing system300provides a generally increased vertical spacing between printing station244and media web270(as compared to the nominal vertical spacing provided in the first configuration302). In one aspect, the position of media web270is measured at a top portion of first roller262or at top portion382of intermediate support266) to enable achieving proper print-to-media spacing (i.e., pen-to-paper spacing).

Embodiments of the present disclosure provide a convertible, hybrid printer that allows printing with either a flexible media or rigid media and which includes different types of heaters on opposite sides of a print-heat zone so that the appropriate type of heating is readily available, regardless of whether the flexible media or the printed media is being printed upon.