Space efficient multi-sheet buffer module and modular printing system

Disclosed are a sheet buffer module and a printing system incorporating the buffer module. The buffer module has parallel first and second sheet transport paths that extend in opposite directions across a frame. Sheet buffer paths connect the first sheet transport path to the second sheet transport path. In operation, a stream of sheets is fed by the first sheet transport path from a multi-color printing module to a monochrome printing module. During this process, selected sheets are diverted from the stream into the sheet buffer paths and held. After processing by the monochrome printing module, the stream is fed by the second sheet transport path back to the multi-color printing module for further processing and/or final output. During this process, the sheet buffer paths feed the buffered sheets into the second sheet transport path such that they are inserted at the proper locations back into the stream.

BACKGROUND AND SUMMARY

This application is related to the following applications filed concurrently herewith by the same Applicants and assigned to the same Assignee: U.S. Pat. No. 7,946,582, Issued May 24, 2011 and U.S. Pat. No. 8,128,088, Issued Mar. 6, 2012. The complete disclosures of these co-pending applications are incorporated in their entirety herein by reference.

Embodiments herein generally relate to modular printing systems and, more particularly, to embodiments of a multi-sheet buffer module and a modular printing system incorporating such a multi-sheet buffer module.

Modularity in printing systems is known. For example, U.S. patent application Ser. No. 12/211,853 of Bober et al., filed on Sep. 17, 2008, and U.S. patent application Ser. No. 12/331,768 of Mandel et al., filed on Dec. 10, 2008 (both of which are assigned to Xerox Corporation of Norwalk, Conn., USA, and incorporated herein by reference in their entirety) disclose electrostatographic printing systems comprising multiple modules (i.e., discrete interchangeable units). Each module comprises one or more of the printing system's functional components (e.g., sheet feeders, printing engines, sheet inverters, sheet buffers, finishers, etc.) structurally self-contained within its own supporting frame and housing (i.e., cabinet).

Oftentimes multi-page documents contain both single color (i.e., monochrome) pages and multi-color pages. Since it is more cost and time efficient to print single color pages using a single color (i.e., monochrome) printing engine vice a multi-color printing engine, modular printing systems incorporating heterogeneous printing engine modules (e.g., a single color and multi-color printing engine modules) in a tightly integrated parallel printing (TIPP) architecture have been developed (e.g., see U.S. patent application Ser. No. 12/211,853 of Bober et al. and U.S. patent application Ser. No. 12/331,768 of Mandel et al., incorporated by reference above). Such modular printing systems can print multi-page documents, having single color and multi-color pages. To ensure that the various single color and multi-color pages are printed on print media sheets by the appropriate printing engine(s), a sorting process is performed. Once printed, the single color and multi-color pages are merged in order to output the finished document. However, timing of sheet output from the different print engines to ensure proper page merging (i.e., to ensure that pages are in the proper order) presents a problem for a number of reasons. For example, since multi-color print engines are typically more costly to run and since multi-page documents typically have significantly more text-only pages than multi-color pages, it is more cost efficient to print all or batches of multi-color pages together. This minimizes the number of on-off and warm-up cycles performed by the multi-color printing engine during a single print job, but results in multi-color pages being printed out of order and, particularly, early. Timing of sheet output is further made difficult as a result of duplex printing and mixed printing (i.e., when a single sheet requires printing by one side by a single color printing engine and on the opposite side by a multi-color printing engine).

In view of the foregoing, disclosed herein are embodiments of a multi-sheet buffer module and a modular printing system incorporating the multi-sheet buffer module. The buffer module has parallel first and second sheet transport paths that extend in opposite directions (i.e., transport sheets in opposite directions) across a support frame. Multiple parallel sheet buffer paths extend from the first sheet transport path to the second sheet transport path. In operation, a stream of sheets (e.g., unimaged sheets, sheets previously printed in simplex or duplex format by the first printing module, etc.) is received by the first sheet transport path from a first printing module (e.g., a color printing module) and fed through to a second printing module (e.g., a single color printing module). During this process, selected sheets are diverted from the stream into the sheet buffer paths and held. After processing by the second printing module (e.g., simplex or duplex printing), the stream of sheets is received by the second sheet transport path and fed through to the first printing module for further processing and/or for final output, for example, to a finishing module. During this process, the sheet buffer paths will feed the buffered sheets into the second sheet transport path such that they are inserted at the proper locations back into the stream of sheets. Such a multi-sheet buffer module provides a buffering function, as necessary, during the various printing processes (e.g., single color printing in simplex or duplex format, multi-color printing in simplex or duplex format, and mixed printing (i.e., one side single color, one side multi-color)) performed by the different printing modules and further provides a buffering function to ensure that sheets fully printed by the different printing modules are merged in the proper order prior to output.

Generally, embodiments of a multi-sheet buffer module as disclosed herein can comprise a support frame having a first side and a second side opposite the first side. A first sheet transport path can extend across the support frame for transporting sheets in a given direction from a first sheet input port on the first side to a first sheet output port on the second side. Additionally, a second sheet transport path, which is parallel to the first sheet transport path, can extend across the support frame for transporting sheets in the opposite direction from a second sheet input port on the second side to a second sheet output port on the first side. Finally, a plurality of sheet buffer paths can extend between the first and second sheet transport paths for transporting sheets from the first sheet transport path to the second sheet transport path and each of the sheet buffer paths can have a length sufficient to hold one or more print media sheets.

The multi-sheet buffer module, as described generally above, can be configured (as shown) for insertion between two stacked printing modules in a modular printing system. For example, in such an embodiment the support frame can have a bottom side and a top side opposite the bottom side. The first sheet transport path can extend essentially vertically across the support frame for transporting sheets in an upward direction from a first sheet input port on the bottom side of the support frame to a first sheet output port on the top side of the support frame. Additionally, a second sheet transport path, which is parallel to the first sheet transport path, can extend essentially vertically across the support frame for transporting sheets in a downward direction from a second sheet input port on the top side of the support frame to a second sheet output port on the bottom side of the support frame. Finally, a plurality of sheet buffer paths can extend essentially horizontally between the first and second sheet transport paths for transporting sheets from the first sheet transport path to the second sheet transport path.

During operation of the multi-sheet buffer module, the first sheet transport path can receive, at the first input port, a stream of sheets and can feed the stream of sheets out the first sheet output port. During this process, at least one sheet buffer path can divert at least one selected sheet from the stream and can hold that selected sheet. Subsequently, the second sheet transport path can receive, at the second input port, the stream of sheets and can feed the stream out the second sheet output port. During this process, any sheet buffer paths holding selected sheets can feed the selected sheets into the second sheet transport path such that they inserted back into the stream at predetermined points. To accomplish this, the buffer module can comprise a controller operatively connected to the first sheet transport path and the sheet buffer paths so as to control movement of sheets within the buffer module. Specifically, each sheet buffer path can have a corresponding gate adjacent to the first sheet transport path and one or more sheet transport devices. Each gate can be selectively controlled (e.g., by the controller) to force selected sheets to enter the sheet buffer paths on demand. Additionally, the sheet transport device(s) in each buffer path can be selectively controlled (e.g., by the controller) to force selected sheets, which are being held, to exit into the second sheet transport path on demand.

The above-described multi-sheet buffer module embodiments can be incorporated into a modular printing system with multiple printing modules in order to arrange sheets within a multi-page document in the proper order prior to output. The multi-sheet buffer module embodiments provide the additional advantage of allowing for sheet buffering during the various printing processes performed by the different printing modules. Specifically, such a modular printing system can comprise a first printing module (e.g., a multiple color printing module), and a second printing module (e.g., a single color printing module). The first printing module and the second printing module in this modular printing system can, for example, operate in tandem to print a multi-page document having single color sheets in simplex or duplex form, multiple color sheets in simplex or duplex form and, optionally, mixed sheets (i.e., sheets with single color printing one side and multi-color printing on the opposite side of the sheet). The multi-sheet buffer module, as described in detail above, can be positioned between the first printing module and the second printing module. For example, in the case of stacked printing modules, the buffer module can be positioned on top of the first printing module and below the second printing module. In this configuration, the multi-sheet buffer can provide any required sheet buffering during the various printing operations performed by the first and second printing modules and can also provide sheet buffering to arrange fully printed sheets within a multi-page document in the proper order prior to output.

During operation of the modular printing system, the first printing module (e.g., the color printing module) can receive unimaged sheets from, for example, a feeder module. Once in the first printing module, some of the sheets can be processed (i.e., can be printed in simplex and/or duplex form by the first printing module) and all sheets (i.e., any unimaged sheets and any printed sheets) can be forwarded in a stream to the buffer module. In the buffer module, the first sheet transport path can receive the stream of sheets at the first input port from the first printing module and can begin feeding this stream of sheets out the first sheet output port into the second printing module (e.g., into the single color printing module). During this process, at least one sheet buffer path can divert at least one selected sheet from the stream and can hold that selected sheet such that the sheet is not passed into the second printing module for processing. Once in the second printing module, the remaining sheets in the stream can be processed (i.e., can be printed in simplex and/or duplex form by the second printing module). Subsequently, the second sheet transport path can receive the stream of sheets at the second input port from the second printing module, as processed by the second printing module, and can begin feeding the stream out the second sheet output port back into the first printing module. During this process, any sheet buffer paths holding selected sheets (i.e., buffered sheets) can feed the selected sheets into the second sheet transport path such that they are inserted back into the stream at a predetermined point. Once back in the first printing module, individual sheets within the stream may be further processed by the first printing module, transported back into the buffering module for further processing as described above and/or finally output, for example, to a finishing module.

DETAILED DESCRIPTION

As mentioned above, modularity in printing systems is known. For example, U.S. patent application Ser. No. 12/211,853 of Bober et al., filed on Sep. 17, 2008, and U.S. patent application Ser. No. 12/331,768 of Mandel et al., filed on Dec. 10, 2008 (both of which are assigned to Xerox Corporation of Norwalk, Conn., USA, and incorporated herein by reference in their entirety) disclose electrostatographic printing systems comprising multiple modules (i.e., discrete interchangeable units). Each module comprises one or more of the printing system's functional components (e.g., sheet feeders, printing engines, sheet inverters, sheet buffers, finishers, etc.) structurally self-contained within its own supporting frame and housing (i.e., cabinet).

Oftentimes multi-page documents contain both single color (i.e., monochrome) pages (e.g., text-only pages) and multi-color pages (e.g., pages with colored graphics and/or images only and pages with a combination of text and colored graphics and/or images). Since it is more cost and time efficient to print single color pages using a single color (i.e., monochrome) printing engine vice a multi-color printing engine, modular printing systems incorporating heterogeneous printing engine modules (e.g., a single color and multi-color printing engine modules) in a tightly integrated parallel printing (TIPP) architecture have been developed (e.g., see U.S. patent application Ser. No. 12/211,853 of Bober et al. and U.S. patent application Ser. No. 12/331,768 of Mandel et al., incorporated by reference above). Such modular printing systems can print multi-page documents, having single color and multi-color pages. To ensure that the various single color and multi-color pages are printed on print media sheets by the appropriate printing engine(s), a sorting process is performed. Once printed, the single color and multi-color pages are merged in order to output the finished document. However, timing of sheet output from the different print engines to ensure proper page merging (i.e., in order to ensure the pages are in the proper order) presents a problem for a number of reasons. For example, since multi-color print engines are typically more costly to run and since multi-page documents typically have significantly more text-only pages than multi-color pages, it is more cost efficient to print all or batches of multi-color pages together. This minimizes the number of on-off and warm-up cycles performed by the multi-color printing engine during a single print job, but results in multi-color pages being printed out of order and, particularly, early. Timing of sheet output is further made difficult as a result of duplex printing and mixed printing (i.e., when a single sheet requires printing on one side by the single color printing engine and on the other side by the multi-color printing engine).

One solution to this problem is to provide a multi-sheet buffer module which receives a merged stream of sheets output by the multiple printing engines, such as the multi-sheet buffer module disclosed in the co-pending patent application “DOUBLE EFFICIENCY SHEET BUFFER MODULE AND MODULAR PRINTING SYSTEM WITH DOUBLE EFFICIENCY SHEET BUFFER MODULE” Ser. No. 12/413,802, incorporated by reference above. Such a buffer module can be configured to divert, into sheet buffer paths, any sheets which have been printed out of order and, particularly, early, to hold those sheets, and to subsequently insert those sheets back into the stream at the proper time. Thus, the pages in the printed document as output from the buffer module and, for example, forwarded to a finishing module, are in the proper order. The Double Efficiency Sheet Buffer Module, however, has the disadvantage of taking up additional floor space, where a space constraint exists.

In view of the foregoing, disclosed herein are embodiments of a multi-sheet buffer module and a modular printing system incorporating the multi-sheet buffer module. The buffer module has parallel first and second sheet transport paths that extend in opposite directions (i.e., transport sheets in opposite directions) across a support frame. Multiple parallel sheet buffer paths extend from the first sheet transport path to the second sheet transport path. In operation, a stream of sheets (e.g., unimaged sheets, sheets previously printed in simplex or duplex format by the first printing module, sheets previously printed in simplex form by the second printing module, etc.) is received by the first sheet transport path from a first printing module (e.g., a color printing module) and fed through to a second printing module (e.g., a single color printing module). During this process, selected sheets are diverted from the stream into the sheet buffer paths and held. After processing by the second printing module (e.g., simplex or duplex printing), the stream of sheets is received by the second sheet transport path and fed through to the first printing module for further processing and/or for final output, for example, to a finishing module. During this process, the sheet buffer paths will feed the buffered sheets into the second sheet transport path such that they are inserted at the proper locations back into the stream of sheets. Such a multi-sheet buffer module provides a buffering function, as necessary, during the various printing processes (e.g., single color printing in simplex or duplex format, multi-color printing in simplex or duplex format, and mixed printing (i.e., one side single color, one side multi-color)) performed by the different printing modules and further provides a buffering function to ensure that sheets printed by the different printing modules are merged in the proper order prior to output.

Referring toFIG. 1, generally, embodiments of a multi-sheet buffer module100as disclosed herein can comprise a support frame101having a first side110and a second side120opposite the first side110. A first sheet transport path131can extend across the support frame101for transporting sheets in a given direction from a first sheet input port111on the first side110to a first sheet output port112on the second side120. Additionally, a second sheet transport path132, which is parallel to the first sheet transport path131, can extend across the support frame101for transporting sheets in the opposite direction from a second sheet input port121on the second side120to a second sheet output port122on the first side110. Finally, a plurality of sheet buffer paths140extend between the first and second sheet transport paths131,132for transporting sheets from the first sheet transport path131to the second sheet transport path132. The first sheet transport path131, the second sheet transport path132and the buffer paths140, can each comprise sheet transport devices170(e.g., as nip apparatuses (as shown) and/or transport belts) that are configured (e.g., with a drive roller) to cause print media sheets entering the path to be transported in a specific direction.

The multi-sheet buffer module100, as described generally above, can be configured (as shown) for insertion between two stacked printing modules (i.e., printers)14,12in a modular printing system, having a “tower” TIPP architecture. For example, in such an embodiment the support frame101can have a bottom side110and a top side120opposite the bottom side110. The first sheet transport path131can extend essentially vertically across the support frame101for transporting sheets in an upward direction from a first sheet input port111on the bottom side110of the support frame101to a first sheet output port112on the top side120of the support frame101. Additionally, a second sheet transport path132, which is parallel to the first sheet transport path131, can extend essentially vertically across the support frame101for transporting sheets in a downward direction from a second sheet input port121on the top side120of the support frame101to a second sheet output port122on the bottom side110of the support frame101. Finally, a plurality of sheet buffer paths140can extend essentially horizontally between the first and second sheet transport paths131,132for transporting sheets from the first sheet transport path131to the second sheet transport path132. This particular embodiment has the advantage of providing a buffer module without increasing the footprint and, thereby the floor area required, for a printing system. However, those skilled in the art will recognize that the multi-sheet buffer module, as described generally above, can also be configured for insertion laterally between non-stacked printing modules.

Regardless of whether the sheet buffer module100is configured to be stacked or not, the buffer module100can be configured with any number of sheet buffer paths140(e.g., 5 as shown, 10, 20, 30, 50, etc.) and each of these sheet buffer paths140can have a length sufficient to hold one or more print media sheets. However, those skilled in the art will recognize that the number of sheet buffer paths140and the length of the sheet buffer paths140are limited by the dimensions of the buffer module100. That is, if the sheet buffer module100is configured to be stacked between printing modules14,12, then the allowable height (e.g., as determined by customer specifications) for the sheet buffer module will dictate the total number of sheet buffer paths that can be incorporated into the sheet buffer module100. For example, if each sheet buffer path140, including sheet transport devices170, requires approximately 2-3 inches of space and if the maximum height183of the sheet buffer module100is set at 18 inches, then the sheet buffer module100may be configured with approximately 6-9 sheet buffer paths140. Furthermore, if the length of the sheet buffer module100is approximately equal to the length181of the printing modules14,12(e.g., between 30 and 50 inches), then the sheet buffer paths140can be configured to have a length182that is only slightly less. Thus, allowing more than one sheet to be buffered in each sheet buffer path140at a time.

During operation of the multi-sheet buffer module100, the first sheet transport path131can receive, at the first input port111, a stream191of sheets and can feed (i.e., can be configured to or adapted to feed) the stream191of sheets out the first sheet output port112. During this process, at least one sheet buffer path140can divert (i.e., can be configured to or adapted to divert) at least one selected sheet192from the stream191and can hold that selected sheet192. Subsequently, the second sheet transport path132can receive, at the second input port121, the stream191of sheets and can feed the stream191out the second sheet output port122. During this process, any sheet buffer path140holding selected sheets192can feed (i.e., can be configured to or adapted to feed) the selected sheets192into the second sheet transport path132such that they are inserted back into the stream191at predetermined points.

To accomplish this, the buffer module100can comprise a controller180operatively connected to the first sheet transport path131and the sheet buffer paths140so as to control movement of sheets within the buffer module100. Specifically, the controller180can access, from an internal or external data storage device, information indicating the proper flow of sheets between the printing modules during printing, indicating the proper order in which printed sheets in the stream191are to be in prior to final output and also indicating the actual order of the sheets within the stream191. Based on this information, the controller180can determine (i.e., can be configured to or adapted to determine) which sheets require buffering (e.g., either during the various printing processes performed by the different printing modules14,12or to ensure that sheets printed by the different printing modules are merged in the proper order prior to output), can select (i.e., can be configured to or adapted to select) those sheets, and can cause (i.e., can be configured to or adapted to cause) the buffer module100to perform the required buffering. Those skilled in the art will recognize that controller180can be programmed with computer usable program code and can further comprise a processor adapted to execute the code in order to perform these functions.

More particularly, based on an analysis of information pertaining to the proper flow of sheets between the printing modules14,12during printing, the proper order in which printed sheets in the stream191are to be in prior to final output and the actual order of the sheets within the stream191, the controller180can cause gates160to divert, into the sheet buffer paths140, one or more selected sheets192from the stream191as it passes through the first sheet transport path131. Subsequently, the controller180can cause sheet transport device(s)170within the sheet buffer paths140to insert those selected sheets192back into the stream191as it passes through the second sheet transport path132at the proper moment.

Specifically, each sheet buffer path140can have a corresponding gate160adjacent to the first sheet transport path131. Each gate160can be positioned at the intersection between the first sheet transport path131and its corresponding sheet buffer path140. Actuation of each gate160can be selectively controlled (e.g., by the controller180) to either allow sheets to pass along the first sheet transport path131directly to the first sheet output port112or to force sheets to divert into (i.e., enter into) the corresponding sheet buffer path140on demand. For example, each gate160can be configured as a baffle or diverter capable of pivoting movement in order to control the direction a sheet travels (i.e., along the first sheet transport path131or into a corresponding sheet buffer path140). The pivoting movement of each gate160can be individually and automatically controlled by the controller180.

Additionally, each sheet buffer path140can further have one or more sheet transport devices170positioned so as to ensure that any sheet held within a sheet buffer path140can be engaged and transported to the second sheet transport path132. Actuation of individual sheet transport devices170(e.g., nips, as shown, or electrostatic transport belts) within the sheet buffer paths140can be selectively controlled (e.g., by the controller180) to allow any one specific sheet192to maintain its position within a specific sheet buffer path140or to force any one specific sheet192being held within a specific sheet buffer path140to exit the sheet buffer path140and thereby, enter the second sheet transport path132on demand. For example, each sheet transport device170can be configured with a conventional drive roller, which rotates so as to directly (e.g., in the case of nips) or indirectly (e.g., in the case of transport belts) cause a sheet to move in a given direction. Rotation of each drive roller can be controlled by a motor, which in turn can be individually and automatically by the controller180.

The above-described multi-sheet buffer module100embodiments can be incorporated into any modular printing system with multiple printing modules that requires or that would benefit from sheet buffering during printing and/or in order to output a multi-page document with all pages in the proper order. For example, the multi-sheet buffer module100, described in detail above, can be incorporated into a modular printing system such as that disclosed in U.S. patent application Ser. No. 12/211,853 of Bober et al. (incorporated by reference above).

Specifically,FIG. 2provides an illustration of a modular printing system10as disclosed in U.S. patent application Ser. No. 12/211,853 of Bober et al. (incorporated by reference above), having a “tower” TIPP architecture. This modular printing system10provides for single color printing in simplex or duplex format, multi-color printing in simplex or duplex format, and mixed printing (i.e., one side single color, one side multi-color). This modular printing system10outputs a merged stream of single color sheets in simplex or duplex format, multi-color sheets in simplex or duplex format, and, optionally, mixed sheets (i.e., one side single color, one side multi-color) into a finisher module90and would benefit from the incorporation of a multi-sheet buffer module capable of re-ordering sheets from the merged stream, as necessary, prior to processing by the finisher module90. The modular printing system10comprises a sheet feed module11, electronic printers12and14(i.e., printing modules) that include a conventional monochrome marking engine module13and a conventional color image marking engine module (IME)15, respectively, and a paper transport path leading into and out of each printer that includes media path modules20and30connecting these three modules and associated for tightly integrated parallel printing of documents with the system. Finished output from the printing system is sent to a conventional finisher90.

For simplex monochrome copies, feeder module11includes a plurality of conventional sheet feeders that feed sheets into a media path highway57and into a conventional diverter gate system58that conveys the sheets into upper media path module20and on to transfer station17to have images from IME13transferred thereto. The sheets are then transported through fuser18and into inverter53where the sheet is inverter for proper face down output collation exiting to the vertical path19, through a diverter gate system55, decurler40and into finisher90. Alternatingly, unimaged sheets from sheet feed module11are fed downward through the diverter gate system58into vertical transport16and through lower media path module30to transfer station50to receive images from IME15. The sheets are then transported through fuser52, into inverter54for proper face down output collation, exiting into vertical transport56, through diverter gate system55and through decurler40en route to conventional finisher90accepts unstapled sheets in upper catch tray92or stapled sheet at93in intermediate catch tray95or sheets stapled at97in booklet maker96and folded into booklets at folder98and outputted onto lower catch tray99. Control station60allows an operator to selectively control the details of a desired job. Optionally, an insert or interposed sheet, such as, a cover, photo, tab sheet or other special sheet can be inserted into the first printer engine from an auxiliary sheet feed source (not shown) through sheet input65, if desired.

For color image duplexing, sheets can be fed from feeder module11through diverter system58, into color electronic printer14and downward along vertical transport16to lower media path module30and on to transfer station50to receive images on a first side thereof from IME15that includes cyan, magenta, yellow and black developer housings. Afterwards, the sheets are forwarded through fuser52and into inverter54. The sheets leave inverter54trail edge first and are fed upwards along media transport path56and into media path highway57, through diverter gate systems55and58and eventually downward along vertical transport16and back to lower media path module30and again through transfer station50to receive images onto a second side of the sheets. The sheets are then fused at fuser52and transported upward along media path56, through diverter gate system55and out through decurler40and into finisher90. For monochrome image duplexing, sheets can be fed from feeder module11through diverter gate system58, into monochrome electronic printer12and into the media path module20and on to transfer station17to receive monochrome images on a first side thereof from IME13that includes a black developer housing only. Afterwards, the sheets are forwarded through fuser18and into inverter53. The sheets leave inverter53trail edge first and are fed downwards along media transport path19, through diverter gate system55and into media path highway57, through diverter gate system58and back to upper media path module20and again through transfer station17to receive monochrome images onto a second side of the sheets. The sheets are then fused at fuser18and transported downward along media path19, through diverter gate system55and out through decurler40and into finisher90. Or alternatingly, combinations of one side monochrome and one side color imaged duplexed sheets can be produced by using these same media path elements in the appropriate sequences.

Referring toFIG. 3in combination withFIG. 1, the multi-sheet buffer module100ofFIG. 1can easily be incorporated into the modular printing system10ofFIG. 2or any other similar stacked or unstacked modular printing system which provides for single color printing in simplex or duplex format, multi-color printing in simplex or duplex format and, optionally, mixed printing (i.e., one side single color, one side multi-color). Specifically, such a modular printing system10can comprise a first printing module14and a second printing module12. The first printing module14can, for example, comprise a multiple color printing module configured with a multiple color printing engine15. The second printing module30can, for example, comprise a single color (i.e., monochrome) printing module configured with a single color printing engine13. Various sheet transport paths and, optional, inverters can extend between and through the printing engine modules14,12, as described above.

The first printing module14and the second printing module12in this modular printing system10can, for example, operate in tandem (i.e., can be adapted to or configured to operate in tandem) to print a multi-page document having single color sheets in simplex or duplex format, multiple color sheets in simplex or duplex format, and, optionally, mixed sheets (i.e., one side single color, one side mixed color). The multi-sheet buffer module100, as described in detail above, can be positioned between the first printing module14and the second printing module12. For example, in the case of stacked printing modules (i.e., a tower TIPP architecture), the buffer module100can be positioned on top of the first printing module14and below the second printing module12. In this configuration, the multi-sheet buffer100can provide any required sheet buffering during the various printing operations performed by the first and second printing modules14,12and can also provide sheet buffering to arrange sheets within a multi-page document in the proper order prior to output.

During operation of the modular printing system10, the first printing module14(e.g., the color printing module) can receive unimaged sheets (i.e., blank sheets) from, for example, a feeder module11. Once in the first printing module14, some of the sheets can be processed (i.e., can be printed in simplex and/or duplex form by the first printing module14), as discussed above, and all sheets (i.e., any unimaged sheets and any printed sheets) can be forwarded in a stream191to the buffer module100.

In the buffer module100, the first sheet transport path131can receive the stream191of sheets at the first input port111from the first printing module14and can beginning feeding this stream191of sheets out the first sheet output port112into the second printing module120(e.g., into the single color printing module). During this process, at least one sheet buffer path140can divert at least one selected sheet192from the stream191and can hold that selected sheet such that the sheet192is not passed into the second printing module12for processing.

Once in the second printing module12, the remaining sheets in the stream191can be processed (i.e., can be printed in simplex and/or duplex form by the second printing module14). Subsequently, the second sheet transport path132can receive the stream191of sheets at the second input port121from the second printing module12, as processed by the second printing module12, and can begin feeding the stream191out the second sheet output port122back into the first printing module14. During this process, any sheet buffer paths140holding selected sheets192(i.e., buffered sheets) can feed the selected sheets192into the second sheet transport path132such that they are inserted back into the stream191at a predetermined point. Once back in the first printing module14, individual sheets within the stream191may be further processed by the first printing module14(e.g., to allow for mixed printing when one side of a sheet is to be printed using a single color and another side of the same sheet is to be printed using multiple colors), transported back into the buffering module prior to additional processing (e.g., to allow for efficient scheduling during mixed printing) and/or finally output, for example, to a finishing module90. Thus, the disclosed printing system10allows sheets from both the first and second printing modules14,12to access the buffer module10, as necessary, before final output.

It should be understood that the controller180described above and illustrated inFIG. 1can be integrated into the control station60of the modular printing system10ofFIG. 3. The control station60can preferably comprise a programmable, self-contained, dedicated mini-computer having a central processor unit (CPU), electronic storage, and a display or user interface (UI) and can function as the main control system for the multiple modules (e.g., the feeder module, printing engine modules, sheet buffer module, etc.) within the modular printing system10.

It should further be understood that the terms “image printing device”, “printing device”, “printing engines”, “printing machine”, “printer”, “printing system”, etc., as used herein encompass any of a digital copier, bookmaking machine, facsimile machine, multi-function machine, etc. which performs a print outputting function. The details of printing devices (e.g., printers, printing engines, etc.) are well-known by those ordinarily skilled in the art. Printing devices are readily available devices produced by manufactures such as Xerox Corporation, Norwalk, Conn., USA. Such printing devices commonly include input/output, power supplies, processors, media movement devices, marking devices etc., the details of which are omitted herefrom to allow the reader to focus on the salient aspects of the embodiments described herein. Additionally, the term “print medium” as used herein encompasses any cut sheet or roll of print media suitable for receiving images, pictures, figures, drawings, printed text, handwritten text, etc. Exemplary print media include, but are not limited to, a paper, plastic, and vinyl. Finally, the phrase “stream of sheets” as used herein refers to print media sheets transported in succession (i.e., one after another) through a sheet transport path.

It should further be understood that the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims. The claims can encompass embodiments in hardware, software, and/or a combination thereof. Unless specifically defined in a specific claim itself, steps or components of the embodiments herein should not be implied or imported from any above example as limitations to any particular order, number, position, size, shape, angle, color, or material.

Therefore, disclosed above are embodiments of a multi-sheet buffer module and a modular printing system incorporating the multi-sheet buffer module. The buffer module has parallel first and second sheet transport paths that extend in opposite directions (i.e., transport sheets in opposite directions) across a support frame. Multiple parallel sheet buffer paths extend from the first sheet transport path to the second sheet transport path. In operation, a stream of sheets (e.g., unimaged sheets, sheets previously printed in simplex or duplex format by the first printing module, sheets previously printed in simplex form by the second printing module, etc.) is received by the first sheet transport path from a first printing module (e.g., a color printing module) and fed through to a second printing module (e.g., a single color printing module). During this process, selected sheets are diverted from the stream into the sheet buffer paths and held. After processing by the second printing module (e.g., simplex or duplex printing), the stream of sheets is received by the second sheet transport path and fed through to the first printing module for further processing and/or for final output, for example, to a finishing module. During this process, the sheet buffer paths will feed the buffered sheets into the second sheet transport path such that they are inserted at the proper locations back into the stream of sheets. Such a multi-sheet buffer module provides a buffering function, as necessary, during the various printing processes (e.g., single color printing in simplex or duplex format, multi-color printing in simplex or duplex format, and mixed printing (i.e., one side single color, one side multi-color)) performed by the different printing modules and further provides a buffering function to ensure that sheets printed by the different printing modules are merged in the proper order prior to output. In a “tower” TIPP modular printing system architecture, such a sheet buffer modules, provides the added advantage of not increasing the overall footprint of the printing system.