Media print system

A media print system includes a first print unit, a second print unit, at least one actuator configured to move the first unit and the second unit relative to one another and a controller configured to generate control signals. The at least one actuator positions the first unit and the second unit at the first and second positions, respectively, during a first longitudinal pass of a medium and positions the first unit at a third position during a second longitudinal pass of the medium in response to the control signals.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

Media print system10generally includes media transport14, print unit16, print unit18, actuator20, actuator22, service station24, service station26and controller28. Media transport14comprises a device configured to move media12relative to print units16and18. In one embodiment, media transport14is configured to longitudinally move a first medium having a first transverse dimension and a second medium having a second greater transverse dimension. In particular, media transport14is configured to move media12in a longitudinal direction as indicated by arrow32. Media transport14is further configured, according to some embodiments, to move media12through one or more passes relative to print units16,18. In one embodiment, media transport14may comprise a drum, a belt or a series of rollers configured to engage and rotate or wrap media12about one or more axes so as to move media12through one or more passes relative to print units16,18. In another embodiment, media transport14may alternatively be configured to move medium12in a first direction as indicated by arrow32during a first pass, to reverse its direction so as to move medium12backwards in a direction indicated by arrow34and to once again move medium12in the direction indicated by arrow32for an additional pass relative to print units16,18.

BACKGROUND

Page-wide array printers include an array of ink-dispensing nozzles fixed to a support. To clear paper jams or to service the printheads, the printheads may need to be removed or separated from the support. Such removal of the printheads from the support can be time consuming and tedious. Moreover, it may be difficult to precisely and accurately align and reattach the array of printheads to the support.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS

FIG. 1is a schematic illustration of media print system10according to one exemplary embodiment. Media print system10is configured to print or otherwise form images, such as illustrations, text and the like, upon a print medium12having a transverse dimension TD1. In particular, system10is configured to print across the entire transverse dimension TD1in a single path of medium12. In other embodiments, system10may alternatively be configured to print across an entire transverse print area of media12which may comprise a transverse dimension of media12less the left and right margins of media12which may be dedicated as non-printing areas.

Media print system10generally includes media transport14, print unit16, print unit18, actuator20, actuator22, service station24, service station26and controller28. Media transport14comprises a device configured to move media12relative to print units16and18. In particular, media transport14is configured to move media12in a longitudinal direction as indicated by arrow32. Media transport14is further configured, according to some embodiments, to move media12through one or more passes relative to print units16,18. In one embodiment, media transport14may comprise a drum, a belt or a series of rollers configured to engage and rotate or wrap media12about one or more axes so as to move media12through one or more passes relative to print units16,18. In another embodiment, media transport14may alternatively be configured to move medium12in a first direction as indicated by arrow32during a first pass, to reverse its direction so as to move medium12backwards in a direction indicated by arrow34and to once again move medium12in the direction indicated by arrow32for an additional pass relative to print units16,18.

Print units16and18(also known as printhead carriages) comprise units configured to print or otherwise form images on a surface of medium12. In the particular example shown, units16and18are configured to deposit a fluid, such as ink, upon medium12. In the particular example shown, each of print units16,18comprises a set of printheads for selectively ejecting and depositing distinct fluids upon medium12. In the example shown, each of units16,18includes printhead40, printhead42and printhead44. According to a specific, non-limiting example embodiment, each of printheads40,42and44have a transverse width of at least 4.25 inches such that units16,18have a combined transverse width of 8.5 inches, enabling units16and18to simultaneously print across an entire transverse dimension TD1of a medium12having a transverse dimension of 8.5 inches. In other embodiments, the printheads of units16and18may have a transverse width of greater than or less than 4.25 inches.

In the particular example shown, printhead40is configured to print a clear fixer fluid. Printhead42is configured to print black and yellow inks. Printhead44is configured to print magenta and cyan inks. In other embodiments, printer units16,18may include a greater or fewer number of such printheads. In other embodiments, the printheads of units16and18may be alternatively configured to print other fluids or other colors of ink. According to one exemplary embodiment, each of printheads40,42and44comprise inkjet printheads. In other embodiments, other fluid dispensing mechanisms may be employed to eject or otherwise deposit ink or other fluid upon medium12.

Actuators20and22comprise mechanisms configured to transversely move print units16and18in the directions indicated by arrows48and50along axes52and54, respectively, relative to medium12. In one embodiment, actuators20and22may comprise electrical motors which drive a belt connected to units16and18to move units16and18along a rod or bar (not shown). In still other embodiments, actuators20and22may comprise other devices configured to move units16and18. Although units16and18are illustrated as having distinct actuators20,22, units16and18may alternatively be driven by a single actuator.

Service stations24and26comprise stations configured to service units1-6and18, respectively. In the particular example shown in which printheads40,42and44include multiple fluid ejecting nozzles574(shown inFIG. 7), service stations24and26are configured to perform multiple servicing operations. Service stations24and26each include a spitting substation60, a wiping substation62and a capping and nozzle detection substation64. Substation60comprises a blotter configured to absorb ink or other fluid fired or spit from the nozzles of printheads40,42and44. In one embodiment, substation60includes a fiber or other absorbing material. In other embodiments, substation60may omit a blotter.

Wiping substation62includes one or more tools configured to apply fluid, such as a solvent, to the nozzles of printheads40,42and44and to wipe or otherwise remove the applied solvents from the nozzles. In one embodiment, substation62may include a solvent pad formed from a compliant material such as tight-celled foam sponge. Examples of solvents that may be applied include water for water-based inks or reactive solvents such as polyethylene glycol. Substation62may additionally include a compliant or elastomeric blade or an absorbent cloth configured to remove fiber or other foreign materials off of the surface of the nozzles of printheads40,42and44and to remove remaining solvent. In other embodiments, wiping substation62may merely include the blade while omitting the application of wiping station fluid.

Capping and nozzle detection substation64is configured to cap the nozzles of printheads40,42and44at the end of servicing. Prior to printing, substation24uncaps the printheads to enable additional printing. Substation64is further configured to detect or otherwise identify the health of the nozzles of printheads40,42and44. According to one embodiment, the nozzles of printheads40,42and44are fired and the resulting ejection of ink is detected to identify clogged or malfunctioning nozzles. Although service stations24and26are illustrated as performing each of the aforementioned servicing operations, servicing stations24and26may alternatively be configured to perform a fewer or greater number of such servicing operations.

Controller28generally comprises a processor unit in communication with media transport14, print units16,18, actuators20,22and service stations24,26. For purposes of the disclosure, the term “processing unit” shall include a conventionally known 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. Controller28is not limited to any specific combination of hardware circuitry and software, nor to any particular source for the instructions executed by the processing unit.

In the particular embodiment shown, controller28receives feedback in the form of electrical signals from media transport14, actuators20,22, print units16,18and service stations24and26and generates control signals which direct the operation of media transport14, print units16,18, actuators20,22and service stations24,26. For example, controller28may receive signals from an encoder of media transport14, wherein the signals indicate the positioning of media. Based upon the sensed position of the media, controller28directs print units16,18as well as actuators20and22to print upon the media. Based upon the sensed need for servicing, controller28may generate control signals directing actuators20,22to reposition print units16,18to service stations24,26. Controller28further generates control signals directing the operation of one or both of service stations24,26.

In one embodiment, controller28may communicate via wires. In another embodiment, controller28may communicate the infrared, RF or other wireless signals. In one embodiment, controller28may be provided as part of a printer. In another embodiment, controller28may be provided as part of computer, network or other device connected to printer including one or more of the remaining components of print system10.

As shown byFIG. 1, controller28is configured to generate control signals which direct actuators20and22to move print units16and18along axes52and54, respectively, relative to one another and relative to print medium12. In the example shown inFIG. 1, controller28generates control signals causing actuators20and22to position print units16and18at offset positions relative to one another such that print units16and18, together, span the entire transverse dimension TD1of medium12or at least an entire print area or print range of medium12(TD1less margins). Controller28further generates control signals directing media transport14to move medium12in the direction indicated by arrow32. As a result, the entire transverse dimension TD1or at least the entire transverse print range or area of medium12may be printed upon during a single pass of medium12.

As shown byFIG. 2, controller28is further configured to generate control signals which direct actuators20and22to move and withdraw print units16and18from medium12to withdrawn positions at service stations24and26, respectively. Because controller28and actuators20and22are configured to move print units16and18to withdrawn positions, servicing and/or repair of media transport14is facilitated. In addition, print units16and18do not obstruct or interfere with clearing or removal of jammed media12. Moreover, because print units16and18may be moved to withdrawn positions, print units16and18may be more easily removed from print system10for servicing, repair or replacement.

Because controller28and actuators20,22are configured to move print units16,18to service stations24and26, respectively, withdrawn from media12, servicing of print units16,18is facilitated without moving or separating print units16,18from a support, carriage, slide rod or other structure associated with actuators20and22and supporting units16,18. In particular, service stations24and26enable spitting, wiping and capping operations to be formed on each of the printheads of print units16and18and also enable health of the nozzles of print units16and18to be determined without removing, realigning, and reattaching units16and18upon the completion of servicing. At the same time, units16and18enable the entire transverse dimension TD1or at least the entire transverse print area or print range of medium12to be simultaneously printed upon in a single pass.

FIGS. 3A and 3Bschematically illustrate media print system10printing or otherwise forming an image upon an alternative medium112having a transverse dimension TD2which is generally greater than the combined transverse widths of print units16and18. In the particular example shown, medium112has a total transverse dimension TD2of approximately 12.75 inches. To print across the entire transverse dimension TD2, units16and18print upon a first portion of medium112during a first pass shown inFIG. 3Aand a second portion of medium112during a second pass as shown inFIG. 3B. In particular, controller28generates control signals which direct actuators20and22to position print units16and18such that print units16and18transversely span transverse region R1. In one embodiment, controller28directs actuators20and22to position print units16and18such that print units16and18partially overlap-one another. Controller28further generates control signals which direct media transport14to move media112through a first pass relative to print units16and18while print units16and18are directed by controller28to eject fluid upon medium112.

As shown byFIG. 3B, upon completion of the first path shown inFIG. 3A, controller28generates control signals which direct actuator20to move print unit16relative to print unit18in the direction indicated by arrow148such that print unit16is located so as to print upon transverse region R2of medium112, wherein R1and R2have a dimension of at least TD2or, alternatively, at least a printable width of medium112. Controller28further generates control signals directing media transport14to move medium112through a second pass while also directing print unit to eject fluid or otherwise print an image upon transverse region R2of medium112. In particular scenarios, controller28may further generate control signals directing print unit18to eject fluid or otherwise form additional imaging upon print medium112. As a result, medium print system10may also be utilized to print or otherwise form images upon media having a transverse dimension or transverse printable area greater than the combined transverse width of print units16,18. AlthoughFIG. 3Bdepicts a scenario wherein only print unit16is moved, controller28may also be configured to generate control signals directing actuator22to transversely move print unit18in yet another position to accommodate even a wider medium or to overprint previously printed upon portions.

FIG. 4is a schematic illustration of media print system10printing upon medium212. In the example shown, controller28generates control signals directing actuators20and22to move print units16and18to positions P1and P2, respectively, transversely spaced from one another. Controller28further generates control signals directing media transport14to longitudinally move medium112through pass1while print units16and18print upon medium212.

Once pass1has been completed, controller28generates control signals directing media transport14to reposition medium212relative to print units16and18for movement through a second pass. In one embodiment, controller28continuously rotates medium212about one or more axes. In another embodiment, controller28generates control signals directing media transport14to reverse the direction of movement of medium212. Controller28further generates control signals directing actuators20and22to reposition print units16and18to positions P3and P4, respectively. Controller28also generates control signals directing media transport14to move medium212through pass2while also directing print units16and18to print upon medium212. As a result, media print system10may print an image across an entire transverse dimension TD3of medium212having a dimension greater than the combined width of print units16and18with two passes of medium212. Because units16and18are spaced from one another while printing during passes1and2, print units16and18do not overlap one another during any one pass and the potential for inks applied by print units16and18during a single pass blending or bleeding into one another prior to becoming fixed or dried is reduced.

FIG. 5schematically illustrates media print system310, another embodiment of media print system10. Media print system310is similar to media print system10except that media print system310includes actuator320in lieu of actuator20and additionally includes print unit317. Those remaining elements of media print system310which correspond to elements of media print system10are numbered similarly.

Actuator320is similar to actuator20except that actuator320is configured to move print units16and317along a common axis52. In one embodiment, actuator320is configured to move print units16and317in unison along axis52. In another embodiment, actuator320is configured to move print units16and317relative to one another along axis52. According to one exemplary embodiment, actuator320may include a pair of individual electric motors configured to rotatably drive a pair of respective belts connected to units16and317so as to move units16and317along a guide such as a slide bar or a rod (not shown) extending along axis52.

Print unit317is substantially identical to print units16and18. In one embodiment, print unit317has a transverse width of at least about 4.25 inches. As a result, print units16,18and317, together, have a combined transverse width of 12.75 inches, enabling media print system310to simultaneously print across medium212in a single pass of medium212by media transport14. Because print units16and317are movable along a common axis52, media print system310compact.

Servicing station325is substantially identical to servicing station24. Servicing station325is positioned along axis52beside service station24. Service325is configured to receive and service print unit317. Print units16and18of media print system10, print units16,18and317of media print system310may be moved by actuators320and22to withdrawn positions, enabling media transport14to be serviced and facilitate the clearing of media jams. At the same time, print units16,18and317may be serviced without being removed or separated from media print system310or actuators320and22.

FIG. 6Aschematically illustrates media print system410, another embodiment of media print system10. Media print system410is similar to media print system10except that media print system410additionally includes print unit417, actuator421and service station425. Print unit417is substantially identical to print units16and18except that print unit417is longitudinally offset relative to print units16and18. Actuator421is similar to actuators20and22except that actuator421is configured to transversely move print unit417along axis453relative to medium212and service station425. Service station425is substantially identical to service stations24and26and is configured to service unit417. Service station425is located along axis453and receives print unit417when print unit417is moved by actuator421to a withdrawn position for servicing of print unit417, for nozzle health detection of print unit417and for clearing of media jams.

In the scenario illustrated inFIG. 6A, controller28generates control signals directing actuators20,22and421to transversely move print units16,18and417, respectively, to the transversely staggered positions. In the staggered positions, print units16,18and417, together, transversely span the entire transverse dimension TD2of medium212. In one embodiment, print units16,18and417may slightly overlap one another. Controller28further generates control signals directing media transport14to longitudinally move medium212while also directing one or more print units16,18and417to eject ink or otherwise print upon medium212. As a result, media print system410simultaneously prints across the entire transverse dimension TD2of medium212in a single pass of medium212.

FIG. 6Billustrates media print system410during a second pass of the medium212relative to print units16,18and417. In the scenario shown inFIG. 6B, higher quality printing may be achieved by printing over the same area of medium212several times to reduce issues with color, optical density and reduce coalescence. As shown byFIG. 6B, during the second pass, print units16,18and417are repositioned so as to print across the regions of medium212which were printed upon by another print unit during the first printing pass. As a result, errors caused by the malfunctioning of portions of one or more of printheads16,18and417are hid. For example, if a particular nozzle of print unit16is malfunctioning, the unprinted upon portion of medium212may be printed upon by a properly functioning nozzle of print unit18during the second printing pass. In this manner, malfunctioning nozzles or other image-forming portions associated with a particular print unit may be corrected or addressed by repositioning the other print units. In lieu of hiding a printing omission caused by a malfunctioning nozzle or printing component of a first print unit with a properly functioning nozzle or printing component of a second print unit, such errors may be corrected by indexing each print unit through a small distance along axes52,54and453such that printing errors caused by malfunctioning nozzles or print components of a first print unit are addressed or corrected using properly functioning nozzles or printing portions of the same print unit.

FIG. 7is a side elevational view schematically illustrating media print system510, one example of media print system410shown inFIG. 6. Media print system510includes media transport514, print units16,18and417, actuators20,22(shown inFIG. 6) and 421, service stations24,26(shown inFIG. 6) and 425, and controller28. As shown byFIG. 7, in one embodiment, print units16,18and417each include ink reservoirs570and printheads572. Printheads572each include a plurality of nozzles574(schematically illustrated) through which ink is ejected onto media212and213.

As further shown byFIG. 7, media transport514includes drum576and actuator578. Drum576generally comprises an elongate cylinder configured to be rotated about axis580. Drum576is further configured to support one or more sheets of media, such as media212and213, which wrap about an exterior surface of drum576. In one embodiment, drum576may include vacuum source and one or more surface vacuum ports for drawing and holding media to drum576. In particular embodiments, drum576may additionally include internal heaters for heating the surface of drum576to facilitate the drying of the ink upon the media supported by drum576.

Actuator578comprises a rotary actuator configured to rotatably drive drum576about axis580. In operation, controller28generates control signals which direct actuator578to rotate drum576about axis580while media212and213are wrapped about drum576. Each revolution of drum576about axis580completes a single pass of media212and213relative to print units16,18and417. Because media transport514rotates media212and213about axis580, media212and213do not need to be reversed or backed up for being printed upon during subsequent passes.

Overall, media print systems10,310,410and510enable simultaneous printing upon an entire transverse direction of a medium during a single pass of the medium. At the same time, systems10,310,410and510also enable mediums having transverse dimensions greater than the combined transverse width of the multiple print units to be printed upon. Because systems10,310,410and510enable print units16,18and417to be withdrawn from the medium, media transport14,514may be serviced and media or paper jams may be cleared without interference from print units. Moreover, systems10,310,410and510also enable print units16,18,317and417to be withdrawn from the medium for servicing without detaching such print units from their actuators and without realigning during reattachment.