Method and apparatus for scoring media

A method and apparatus for printing and scoring media in a printing system. In one embodiment a scoring pattern is based upon input by the user on a graphical user interface. The system typically incorporates a controller that drives a scoring printer having a scoring head with one or more pins or wires that impact the surface of media and weaken the media. By creating a predetermined pattern of impacts, the media is weakened along a region or line for subsequent separation.

RELATED APPLICATIONS

FIELD OF THE INVENTION

This invention relates to a printer system that prints on a media and additionally scores the media in a pattern chosen by the user.

BACKGROUND OF THE INVENTION

Printers have been equipped with cutting devices so that a printed media can be cut at the end of the printing operation without removing the media from the printer. A typical system involves passing a rotary or fixed cutting blade across the media after the printing operation has been completed. Examples of these systems are disclosed in U.S. Pat. Nos. 5,363,123, 5,881,624, 5,296,872, and 5,882,128. These systems are designed to cut along a straight line across the media after the printing operation. However, if a user wishes to cut a line that is curved or angular, or cut out a closed shape from the media, these systems are inadequate. The user must cut the media in a separate operation after removing the media. U.S. Pat. No. 6,117,061 discloses system for printing upon removable portions of a two-dimensional media sheet. The removable portions are removed after printing and folded into three-dimensional shapes. This system, however, requires that the media be first scored or perforated before it is inserted into the printer, so that the removable portions can be removed from the media after printing.

What the prior-art systems lack is a means integrated with the printer that allows complex shapes to be cut or scored into the media as part of the printing operation.

BRIEF SUMMARY OF THE INVENTION

An aspect of the present invention involves a computer based system and method for scoring media. The system in accordance with one exemplary embodiment comprises a central processing unit, a display, a user manipulatable input device, graphical user interface and a scoring printer. Another aspect of the invention involves a scoring head which may be mounted separately from a printhead, but in some instances may be on a same carriage as the printhead. Some embodiments provide scoring with a moving scoring head that allows scoring of the media such as paper during the printing operation.

DETAILED DESCRIPTION OF THE INVENTION

Reference is now made to FIG.1. Using a scoring system according to an embodiment of the present invention21a graphical representation22of a digital file or files, such as a document, is presented to appear upon a display or monitor23that is connected to a computer CPU24. One or more input devices27can be used to edit the graphical representation22prior to generating a hardcopy output on a printer30. The edited graphical representation22depicts elements and objects25of the file as they will appear after printing on a media, such as paper. The CPU24is typically a personal-type computer with a Graphical User Interface (GUI) operating system, such as, for example, any of the Microsoft Windows™ operating systems, UNIX, LINUX, Apple Macintosh OS™, and the like. The digital files are any suitable digital files that are stored in any suitable memory device (hard drive, RAM, ROM, etc.) in the CPU and that contain graphical data for generating instructions for a printer. Such graphical data can include, for example, text with font and other formatting information, and bitmapped or vector-based graphics. Such digital files include those produced by WYSIWYG (what you see is what you get)-type software applications or programs, which include word processing systems, desktop publishing programs, drawing and paint programs, computer aided drafting programs, digital photo applications, as well as any program or application that produces, opens or displays formatted text and/or graphics for printing.

As shown inFIG. 2, a graphical representation22may contain text-type19and/or graphic-type18information which are depicted on the graphical representation as composite displays of printable objects25. The representation also shows scoring indicia26, which are more fully described below. The printed media or sheet22A has corresponding textual and graphical elements19A,18A, respectively, that correspond to the appearance of the corresponding elements19,18in the graphical representation. The printed sheet22A also has score lines26A at the locations of the corresponding scoring indicia26in the graphical representation. The sheet22A is separated along the scored lines to create accepted portions of a desired shape containing the printable objects. The remaining rejected portions can then be discarded.

Reference is now also made toFIG. 3, which is a detailed view of another graphical representation22. The graphical presentation22on the monitor23the file represents the appearance of the file when it is printed. The graphical representation22can be generated by customized software or the application software used to create the file. In most software applications, this is accomplished using its Print Layout or Print Layout feature, or equivalent. Score indicia26(SeeFIG. 2) are then added to the graphical representation22using the user manipulatable input device27, which may be, for example, a mouse, graphics tablet, joystick, touch pad, or keyboard (see FIG.1). The score indicia26represent locations where scores will occur on the final document. Customized drawing-type software can be used for this function, or, alternately, “drawing” tools in the main application can be used. Using Microsoft Word 2000 as an example, while in Print Layout mode the Line tool is selected from the Draw toolbar and a line drawn over the display where a score line is desired. Other suitable tools, such as the Rectangle and Oval, could also be selected. The requirement is that a distinctive indicia indicating the position of the scores on the printed document be added to the graphic image, which indicia can be interpreted for the printer30as score lines or regions.

To differentiate indicia indicating a score26from other indicia and objects, such as those that are to be printed, the score indicia26can be given a distinct property, such as color or style, that isn't otherwise used in the file to identify indicia or objects. Using suitable software, that distinctive property is interpreted for the printer as a score line. Implementation of such software is straightforward, and could be accomplished much the same way colors or other properties are handled by printing subroutines. For example in certain prior-art printers, colors on a print preview display are interpreted for the printer by the print driver as a printable color or a printable shade of gray. In the present invention, instead of a printable color, the displayed color can be interpreted for a scoring printer of the invention as a score. The scoring printhead or apparatus in the printer is then activated by the software and the CPU in the same way a color printhead is activated. This could be done in the application by an add-on module to the main application or in a separate module from the main application, such as in a print driver. Using a print driver accessible to all applications, the invention could be used universally for any graphical application on the CPU if, for example, the driver is configured to score whenever a certain color or property in an application is displayed. Any application displaying that color or property for printing will activate the scoring mechanism of the printer. Print subroutines in the applications that create the digital files can also be suitably modified. In certain high-end graphic applications several existing indicia properties may be available. For example, in a high-end graphics application like AutoCad™ or CorelDraw™, the score indicia could be distinguished by any one of or a combination of layer, line width, line style, and line color of the indicia. With the multitude of colors and properties supported by most applications, a distinctive “score” property visible as a contrasting color or style in the displayed graphical representation22would be practical to achieve. This system would also allow a user to create an unscored draft copy on a media where the score regions are represented by printing. This could be done by using a non-scoring printer to print or by selectively disabling the scoring feature in the scoring printer of the invention. The score indicia may also be added by a software module that is entirely separated from the main application where the score indicia are distinguished by a new software “score” property, label or flag that can be interpreted as a score for the scoring printer.

In any event, the digital file or files represented on the graphical interface are modified by adding digital data for the score indicia. These files are then used by appropriate printer software routines to determine the location of graphical data and scores on the final printed document to send the appropriate data to the scoring printer. The files can then be saved and otherwise manipulated as provided by the operating system.

A score in the media, as used herein, is any region in the media that is sufficiently weakened such that under tensile, torsional, folding and/or shear forces that would tend to tear the media, the media will preferentially part or tear at the score. The score may be, for example, in the form a cut partially through the thickness of the media, or a series of perforations through the media. In paper, the score is usually characterized as a region, most often in the form of a line, where paper fibers have been fully or partially cut, or at least damaged.

A score also includes lines or regions where the media is weakened sufficiently to form a fold line, i.e., wherein upon a folding force the media preferentially folds along the fold line. Fold lines can be created by fiber displacement or minor damage to fibers (e.g., seeFIG. 5) resulting from a sparse or widely spaced score pattern (e.g. seeFIGS. 16A,16D),

Since the score indicia26indicate where the printed sheet or media will be scored, the indicia are usually formed as lines to correspond to media scores, which are usually in curved or straight lines. Points, solid shapes, multiple lines, and the like, would usually not be used, but are contemplated by the invention if special circumstances require the same. For example, if the score lines define a complex, convoluted or closely spaced region to be removed, it may be easier to remove a discarded portion if it is entirely weakened by scores in the form of multiple score lines or a completely perforated area. In addition, a score line may be made weaker by double or overlapping lines of scores.

Reference is now made again to FIG.3. The graphical representation22shows graphical or printable objects25depicted as they will appear in the printed document. At locations determined by the user through the user interface27, score indicia26, here in the form of dotted lines, are added, which indicate where the final document is to be scored. The score indicia26define regions28which represent accepted portions of the media, and regions29which represent portions that will be rejected by the user. These regions28,29may be any shape desired by the user, including regular geometric shapes and irregular open or closed shapes, which may include straight, curved, and convoluted lines.

After the scoring indicia26have been added in the graphical representation and the indicia data added to the digital files or files, the files are processed by the CPU and suitable printing data is sent to a scoring printer30of the invention. The printing may be initiated from the software application in the conventional manner by using the normal print or plot commands and routines. Alternately, customized printing/scoring software routines may be used.

Reference is now made to FIG.4. The scoring printer30applies printed images28A to the media sheet22A and applies scoring lines26A to the print media as represented on the graphical representation22. It is preferred that the scoring operation not require additional intervention by the user beyond the adding the graphical scoring indicia. Accordingly, both the printing and scoring are done on the printer without user manipulation of the media. The scoring should be seen by the user as part the “printing” operation. Scoring systems that are incorporated into the printing mechanism and score the media essentially concurrently with the printing are preferred. These may operate in much the same way as in color printers where a second color is printed concurrently with the first color of the image. A scoring head used in tandem with a moving printhead, as described in detail below, is preferred.

Reference is again made to FIG.3and FIG.4. When the document is printed, the printable objects25and score indicia26represented on the graphical representation are respectively formed on a blank media as printed image elements25A and score lines or elements26A, forming the final printed and scored sheet22A. Referring also toFIG. 5, the printed and scored sheet22A can be separated along the score elements26A into accepted portions28A and rejected portions29A by manually tearing the sheet along the score elements26A.

While any media is contemplated by the invention, properties of the media must be considered with the design of the scoring apparatus since the scoring apparatus must physically alter the media. Accordingly, for certain scoring printer designs, a thick media, or a media with a dense or hard surface may be unsuitable. Suitable plastic media are contemplated using a scoring printhead design with pins that cut, rather than tear, the media. However, it is within the skill of a practitioner to adapt the scoring apparatus to any media.

In general, it is contemplated that the main use of the invention is in integration with low volume printer systems used in home and business environments, such as moving head inkjet printer systems used for monochrome and multicolor printing. The scoring apparatus should be designed to successfully score paper media usually used in these types of printers, such as the common 20 to 24 lb inkjet and copier papers, as well as heavier papers up to about 40 lb, and papers with gloss or matte finishes.

Scoring Printer Construction.

One aspect of the invention is now illustrated with reference toFIG. 6, which is a schematic of an imaging section90of a scoring printer of the invention, showing the media91, media path92, printing head93, and scoring head94. The imaging section90is of the moving-head type with a scoring head94and a printing head93mounted in tandem on a moving carriage95that moves, for example, on a horizontal rod96. The carriage95transports both heads93,94across the media surface along a transverse axis. Separate carriages for each head93,94are also contemplated. A media transport97moves the media between the heads93,94and respective media supports98,99in a longitudinal direction along the media path. The printing head93, the media support98, the moving carriage95, the media transport system97and other supporting structures and systems may be essentially the same as that found on known moving head printers. The moving printhead93is of any suitable construction, including inkjet (piezo- or thermal), thermal, and impact dotmatrix. There may also be additional printheads, such as for color printing. For color printing there may be 3 or 4 print heads mounted on the carriage, or a single multichambered print head in the case of an inkjet printer.

While the invention has been described in conjunction with a moving-head printer, it is understood that the scoring head could be used together with other imaging systems, such a moving paper plotter, or a flat bed plotter, with the scoring head mounted with or in a similar manner to the printing head. In addition, the invention could be applied to any imaging system where a scoring head module could be added before or after the imaging step. For example, in a laser imaging system a scoring system according to the invention could be added at the output of the laser imaging system to score printed pages as they come from the imaging system.

The scoring head94is mounted on the carriage95with the print head93. The scoring head94has a scoring mechanism that comprises selectively activated scoring pins. The mechanism of the scoring head is similar to that of a dot-matrix impact printer, except the pins function to perforate the media rather than impact and form an image. Accordingly, the ends of the pins are constructed differently, and there is no ink ribbon or ink transfer associated with the scoring head. In addition, the media support99under the impact area is designed to endure repeated impacts from the scoring pins without serious functional deterioration. Suitable materials for the media support include, but are not limited to, elastomers and plastics, self-healing mat material, neoprene, rubber and polyurethane.

Reference is now made toFIG. 7is a schematic showing a portion of a scoring printer of the invention. The scoring printer ofFIG. 7includes a housing11, shown in part. A roller15holds and transports a sheet22A, on which printed elements25A are formed. Within the housing11is the codestrip32which extends along its major portion across the media between points33,34near its ends where the codestrip32is wrapped ninety degrees around each of two respective stanchions41,51.

The codestrip32is threaded through a carriage61, which carries a printhead93that comprises a transducer holder62and transducer71(such as a thermal-inkjet pen). The carriage is driven to left and right by a drive train81-85.

The drive train includes a servomotor81, which powers a small endless belt82. That belt rotates a driven idler83, which in turn powers a long carriage-connected endless belt84. The latter also encircles an undriven idler85.

Any system is suitable that provides sufficient positional precision for effective coordination of the printhead93and the scoring head94, each positioned in respective locations on the single carriage61. Such a system is disclosed in U.S. Pat. No. 5,276,970, which is hereby incorporated by reference. Suitable systems include transmission-type sensors mounted on the carriage61and work in association with the code strip31as disclosed in U.S. Pat. No. 5,276,970, which is also incorporated by reference.

As the media sheet22ais transported under the carriage61by the media transport15, the carriage is moved to appropriately position the printhead93for application of the printed elements25A and the scoring head94for application of the score elements26A. The scoring head94is mounted on the front edge of the carriage, and the media support99under the scoring head94is of a resilient material to withstand impact from the perforating pins of the scoring head.

Reference is now made toFIG. 8, which shows a scoring printer similar to that shown inFIG. 7except the printhead93is shown on the front of the carriage and the scoring head94is shown on the rear edge of the carriage61. In addition, the media sheet is shown in partial section to better show the resilient media support99under the path of the scoring head94.

Reference is now made toFIG. 9, which shows a scoring printer similar to that shown inFIG. 7except the printhead93and the scoring head94are shown on the front edge of the carriage61.

Perforating Pins for Scoring Printer

The perforating pins are activated in a manner similar to impact printing pins with sufficient force to push the pins through the media. With reference to FIGS.10A—F, which show pin ends from perspective views, the points of the pins are designed to weaken the media. In design of the pins and the print head there is a balance, for the less damage caused by the pins, the more closely the pin penetrations must be to achieve a score line. Thus a penetration that causes only a dimpling is contemplated where the dimples are spaced close enough together to sufficiently weaken the media. For some media-types, such as plastic media, cutting may be required for a tear-line, although dimpling may be sufficient for a fold line.

Accordingly, the pin may have any suitable tip that weakens the media.

As example,FIG. 10A, shows a pointed end.FIG. 10Bshows a pointed end associated with cutting edges to cut the media.FIG. 10Cshows a cutting pin tip shaped like a screwdriver tip.FIG. 10Dis similar toFIG. 10C, but with a slanted and widened cutting chisel-like end.FIGS. 10E and 10Fshow radiating cutters. Symmetrical designs are preferred to avoid bending forces that could deform the pin during penetration or cause premature pin failure.

As described, above, the perforated pins are activated in a manner similar to impact printing pins. In other aspects the operation and construction of the scoring head are essentially the same for an impact printing head. Prior-art color printers have been constructed with two or more print heads mounted in tandem on a moving carriage, and the operation and activation of the print head and scoring head can be accomplished by adapting known tandem print head technology.

Although, there are similarities between impact printing heads and the scoring head of the invention, some considerations must be made in light of the different function of the scoring head. A prior-art impact printing head usually has 9 or 24 impact pins arranged in a linear matrix. The scoring head of the invention may not require as many pins since the “print” resolution requirement of the scores may not be as high as for a printed image. Any head with at least one pin is contemplated. However, sufficient pins should be present so that all of the score perforations in a raster line can be accomplished with one pass of the scoring head. Preferably the scoring head is activated in the same pass that printer heads are activated. The speed of the carriage and timing of pin activations should be adjusted to permit pin penetration of the media while avoiding breakage of the pins. It should be noted that speed is not as high a consideration for the scoring head of the invention as it is for impact printing heads, because scoring usually represents a small portion of the document, and slowing the print carriage to accommodate scoring will not seriously slow the overall printing operation.

The diameter of the perforating wire or pins may also be larger than impact wires to increase strength, where resolution of perforations is not as critical as for printing. The number of wires may optionally be decreased or the wires in the array may be staggered to accommodate the larger diameter. The latter solution also has the advantage that the individual perforations in the media will be closer or overlapping, which increases the weakness of the score.

Impact print heads usually comprise impact pins driven by an electromagnetic coil operably connected to the pin by a lever. For a scoring head the printer, the construction is similar except perforating pins are used in place of the impact pins. For a scoring head the dimensions of the coil and lever may be adjusted to achieve a proper perforating pin throw length, and sufficient penetrating force to allow the perforating pin to penetrate a media. Electromagnetic activated pin systems are common constructions that are suitable for the present invention. Examples of such systems are those disclosed in U.S. Pat. Nos. 5,540,508, 5,518,327, 5,449,239, 5,213,423, 4,767,227, and 5,039,235, which are hereby incorporated by reference. Other systems, using electrodistortion or piezoelectric elements to activate the perforating pin are also suitable. Suitable systems are disclosed in U.S. Pat. Nos. 5,005,994, 5,292,201, which are hereby incorporated by reference.

Scoring Head A

Reference is now made to FIG.11. An exemplary scoring head comprises a plurality of levers114mounted for rotation about axis115, two such levers being illustrated in the figure. Levers114are mounted on rotational axis115via a bearing (not shown) in order that lever114will rotate as indicated by arrow115A. The forward end114A of levers114are each respectively secured to perforating pins or wires103which are moveably supported in one or more guides105in head nose104. Plungers116and117are mounted on either side or opposite sides of axis115of each lever114in alignment with their respective cores110and111. Plungers116and117comprise soft magnetic material, i.e., a high magnetic permeable material such as pure iron, silicon steel, etc. Electric coils101and102are respectively mounted on cores110and111. In the illustration two plungers are shown, but one plunger on either side of the fulcrum may also be used. For two plungers, magnetic influencing means comprises two magnetic circuits which are employed relative to each lever114at opposite sides of rotation center115, one circuit comprising core110and its yoke, plunger116and coil101and the other circuit comprising core111and its yoke, plunger117and coil102.

Lever114illustrated in the upper portion ofFIG. 11is shown in its activated position with its perforating wire103extended from nose104. Lever114in the lower portion ofFIG. 11is shown in its deactivated, rest or standby position wherein perforating wire103is retracted in nose104. In its standby position, lever114is held against abutment119by means of compression spring108.

In operation, plungers116and117of lever114are attracted respectively to cores110and111under the influence of the magnetic flux generated by coils101and102. As a result, lever114is rotated so that its connected wire103extends to a perforating position illustrated in the upper portion ofFIG. 11with the cutting or penetrating end of wire103striking and penetrating paper media22A and striking media support99before plungers116and117contact their respective cores110and111. The magnetic attraction supplied by the magnetic circuit of coils101and102is sufficient to overcome the compression force of spring108and move lever114away from abutment119. Release of lever114, to return the lever to its standby position against abutment119as illustrated in the lower portion ofFIG. 11, is accomplished by termination of current flow in coils101and102and the compression force of spring108.

Besides the employment of two plungers for each lever114, the distance between rotational axis115and lever end114A secured to perforating wire103on one side of lever114is longer than the distance between rotational axis115and plunger117secured on the other side of lever114. This results in greater displacement of lever end114A relative to smaller displacement at plunger117upon rotational movement of lever114to its activated position. These lengths can be adjusted to achieve the proper displacement for penetration of the tip103A of the penetrating wire into the media22A. Since there are two plungers116and117for each lever affixed on opposite sides of rotational axis115, angular movement at lever end114A will be comparatively greater and, in combination with increased striking acceleration of perforating wire103.

Scoring Head B

Another suitable construction of a perforating or scoring head is shown with reference toFIG. 12, which shows the basic operation of the perforating head and the basic construction of parts of a perforating head712. The perforating head includes a plurality of perforating pins such as wires742, each coupled to an electromagnet740by a lever738pivotable about member739and held securely in position by spring member737. Lever738A is shown in a raised position biased upwardly by spring741thereby holding its attached perforating wire in a retracted position so long as its associated electromagnet is not activated. Electromagnets740are energized at appropriate times by a driving current applied through circuit board743and an electromagnetic attracting force generated thereby pulls lever738downwardly to cause its attached perforating wire742to project in the direction indicated by arrow C. Each wire742is preferably supported by one or more guides. Particularly, a tip742A of each wire742is supported by a front end guide member744, which is held in place by a nose746which serves as a guide holding member. A lubricant750is injected into and preferably stays in a portion of the scoring head located behind the front end guide744. Lubricant750may include, for example, naphthene oil, paraffin oil and olefin oil. When perforating wires742are energized, they project in the direction of the print sheet media22A. The print sheet22A is supported by compliant support99.

Scoring Head C

Another suitable design for a scoring head is now described with reference toFIG. 13. Aplurality of perforating wires330disposed in a wire dot head in a generally radial arrangement. InFIG. 13the view is from the side and only two perforating wires are shown. Front cover331has a guide hole331a, which guides the perforating wires330. An armature332composed of a magnetic substance is supported by a leaf spring333. Electromagnet335has a head coil335B wound around a core335A. A printed circuit board336has printed lines and connector terminals (not shown) that supply a current to the electromagnet335.

The armature332is supported on a free end333aA side of the leaf spring333. A base portion330A of each of the perforating wires330is secured to an edge of the armature332. The pointed end330B of each of the perforating wires330is guided to a guide hole331A of the front cover331so that the perforating end330B is directed on the media (not shown) to penetrate the media when current is supplied to the electromagnet.

Scoring Head D

Reference is now made toFIG. 14describing an electrodistortion or piezoelectric scoring head design. A scoring head210is comprises a cylindrical housing212and a plurality of actuators214arranged in the cylindrical housing212. Each actuator214is constituted of a base member216, a movable member218, and a piezoelectric device assembly220. A perforating wire or pin222is fixed to an end of the movable member218.

A detailed structure of the actuator214will now be described with reference to FIG.15. The movable member218is constituted of an armature230and a beam232brazed to the armature230. The perforating wire222is fixed to an end of the beam232. A displacement enlarging mechanism224is constituted of the movable member218and a pair of leaf springs226and228disposed in substantially parallel relationship to each other. The piezoelectric or electrodistortion device assembly220is constituted of a block236fixed to the base member216, a electrodistortion or piezoelectric device234fixed at its one end to the block236, a block237fixed to the other end of the piezoelectric device234, and a movable block238bonded to the block237. One end of the leaf spring226is brazed to the movable block238of the piezoelectric device assembly220, and the other end of the leaf spring226is brazed to the armature230. On the other hand, one end of the leaf spring228is brazed to the base member216, and the other end of the leaf spring228is brazed to the armature230. The piezoelectric device may have any suitable construction, such as disclosed in U.S. Pat. No. 5,292,201.

Suitable Score Patterns from Perforating Pin Scoring Heads

Reference is now made to FIG.16. As indicated above, the function of the scoring head is to create regions of weakness or scores on the media. With the penetrating pin scoring heads of the invention, this may be by any suitable dot pattern. Usually the print head of an inkjet or impact dot-matrix type is constructed with a linear matrix of jet or impact pins with the direction of the matrix generally perpendicular to the movement of the carriage. However, it is contemplated to mount the printing head with the matrix mounted in line with carriage movement. In such a case, the media transport could move or pass the media under the head while print elements are applied.

The scoring head, which preferably has a matrix of linearly mounted penetrating pins, can be mounted in a similar manner to that of the print head. The “image” or pattern of penetrations in the media is made to provide sufficient weakening of the media to create a score. Suitable exemplary patterns are shown inFIGS. 16A-16Das follows:FIG. 16Ais simple line of penetrations;FIG. 16Bis a line of overlapping penetrations;FIG. 16Cis a double line of penetrations; andFIG. 16Dis a sparse or widely spaced score pattern that may be suitable for forming a fold line. Here some of the score pattern lines are shown with penetrations staggered (see FIG.16C), and all the penetrations are shown as evenly spaced. But penetrations in line and/or randomly spaced are also contemplated.

While this invention has been described with reference to certain specific embodiments and examples, it will be recognized by those skilled in the art that many variations are possible without departing from the scope of this invention, and that the invention, as described by the claims, is intended to cover all changes and modifications of the invention which do not depart from the scope of the invention.