Cart with a support surface having a selectively adjustable contour and a printing system sheet stacker incorporating the cart

Disclosed is a cart having a support surface with a selectively adjustable contour for providing essentially uniform support to a load (e.g., a stack of print media sheets) during receiving and storing modes and for facilitating transfer of the load to another support surface during a transferring mode. The cart can comprise a support surface with alternating fixed and movable sections. In the receiving and storage modes, the movable sections can be top aligned with the fixed sections so that the support surface has an essentially planar contour for providing essentially uniform support. In the transferring mode, the movable sections can be dropped lower so that the support surface has a corrugated contour for facilitating transfer of the load (e.g., using an interdigitation technique). Also disclosed is a printing system sheet stacker incorporating such a cart for receiving, storing and transferring of a sheet stack as well as associated methods.

BACKGROUND

The apparatuses and methods disclosed herein generally relate to carts for receiving, storing and transferring loads, such as a cart that can be integrated into the sheet stacker of a printing system in order to receive, store and transfer a stack of print media sheets, as well as associated methods.

Oftentimes, a stacker cart, which is used in conjunction with a sheet stacker in a printing system, will incorporate a ribbed support surface. Within the stacker, print media sheets are received and arranged in a stack on the ribbed support surface. Unfortunately, the support provided to the stack of print media sheets by the ribbed support surface is non-uniform. Such non-uniform support can lead to deformation (e.g., curling) of the sheets within the sheet stack and, particularly, deformation of the bottom sheets in a relatively large sheet stack and deformation of any sheets that are within a relatively small sheet stack and that have edges (e.g., trailing or leading edges) that land between ribs.

SUMMARY

In view of the foregoing, disclosed herein is a cart having a support surface with a selectively adjustable contour for providing essentially uniform support to a load (e.g., a stack of print media sheets) during receiving and storing modes and for facilitating transfer of the load to another support surface during a transferring mode. Specifically, the cart can comprise a support surface with alternating fixed and movable sections. In the receiving and storage modes, the movable sections can be top aligned with the fixed sections so that the support surface has an essentially planar contour for providing essentially uniform support (e.g., to prevent deformation of print media sheets within a stack of print media sheets on the support surface). In the transferring mode, the movable sections can be dropped lower so that the support surface has a corrugated contour for facilitating transfer of the load (e.g., using an interdigitation technique). Also disclosed herein is a printing system sheet stacker that incorporates such a cart for receiving, storing and transferring of a stack of print media sheets as well as associated methods.

More particularly, disclosed herein is a cart. The cart can comprise a frame and a support surface connected to the frame. The support surface can have a top that receives a load (e.g., a stack of paper sheets, of other print media sheets or of other flexible sheets) and can comprise alternating first sections and second sections. The second sections can be fixed to the frame such that the second sections are immovable at the top of the support surface and the first sections can be moveable relative to the second sections. Specifically, the first sections can be movable between a first position comprising an uppermost position, which is top aligned with the second sections (i.e., between a first position aligned with the second sections at the top of the support surface), and a second position, which is lower than the first position relative to the top of the support surface. When the first sections are in the first position, the top of the support surface will have a planar contour so as to provide essentially uniform support to the load (e.g., during load receiving and load storing modes). When the first sections are in the second position, the top of the support surface will have a corrugated contour so as to facilitate transferring of the load to an additional support surface.

Various additional features of the cart are also disclosed for moving the first sections of the support surface to the first position, for holding the first sections of the support surface in the first position, for moving the first sections of the support surface to the second position and for moving the cart back and forth between a load receiving and/or storing location and a load transferring location.

Also disclosed is a printing system sheet stacker that incorporates such a cart. Specifically, the sheet stacker can comprise a housing, having a first opening and a second opening, and a cart, which is manually movable into and out of the housing through the first opening. This cart can comprise a frame and a support surface connected to the frame.

The support surface can have a top that can receive print media sheets (e.g., paper sheets or other flexible print media sheets), which enter the housing through the second opening, such that the print media sheets are arranged in a stack on the top of the support surface. Optionally, the sheet stacker can comprise an elevator within the housing. This elevator can engage and lift the cart such that the top of the support surface is adjacent to the second opening when receiving of the print media sheets is initiated. Furthermore, this elevator can automatically lower the cart as the print media sheets are arranged in a stack.

In any case, the support surface can comprise alternating first sections and second sections. The second sections can be fixed to the frame such that the second sections are immovable at the top of the support surface and the first sections can be moveable relative to the second sections. Specifically, the first sections can be movable between a first position comprising an uppermost position, which is top aligned with the second sections (i.e., between a first position aligned with the second sections at the top of the support surface), and a second position, which is lower than the first position relative to the top of the support surface. When the first sections are in the first position, the top of the support surface will have a planar contour so as to provide essentially uniform support to the stack of print media sheets (e.g., during receiving and load storing modes). When the first sections are in the second position, the top of the support surface will have a corrugated contour so as to facilitate transferring of the stack of print media sheets to an additional support surface.

Various additional features of the printing system sheet stacker and, particularly, the stacker cart are also disclosed for moving the first sections of the support surface to the first position, for holding the first sections of the support surface in the first position, for moving the first sections of the support surface to the second position and for moving the stacker cart back and forth between a sheet stack receiving and/or storing location within the stacker housing and a sheet stack transferring location.

Also disclosed herein is a method of using a cart to receive, store and transfer a load. Specifically, the method can comprise receiving a load (e.g., a stack of paper sheets, of other print media sheets or of other flexible sheets) on a support surface of a cart. This cart can comprise a frame and the support surface can be connected to the frame. The support surface can have a top and can comprise alternating first sections and second sections. The second sections can be fixed to the frame such that the second sections are immovable at the top of the support surface and the first sections can be moveable relative to the second sections. During the process of receiving the load, the first sections can be in a first position comprising an uppermost position, which is top aligned with the second sections (i.e., a first position aligned with the second sections at the top of the support surface). When the first sections are in this first position, the top of the support surface will have a planar contour so as to provide essentially uniform support to the load (e.g., during load receiving and subsequent storing). After receiving the load, the first sections can be moved to a second position that is lower than the first position relative to the top of the support surface. When the first sections are in the second position, the top of the support surface will have a corrugated contour so as to facilitate transferring of the load to an additional support surface. After transferring the load, the first sections can be moved back into the first position in order to receive an additional load.

Various additional method steps are also disclosed for moving the first sections of the support surface to the first position, for holding the first sections of the support surface in the first position, for moving the first sections of the support surface to the second position and for moving the cart back and forth between a load receiving and/or storing location and a load transferring location.

Also disclosed is a method for using a cart in conjunction with a printing system stacker to receive, store and transfer a stack of print media sheets. Specifically, the method can comprise manually moving a cart into a sheet stacker housing through a first opening. This cart can comprise at least a frame and a support surface connected to the frame.

The method can further comprise receiving, by the top of the support surface, print media sheets, which enter the housing through a second opening. Specifically, the print media sheets can be received such that they are arranged in a stack on the top of the support surface. Optionally, prior to receiving the print media sheets, an elevator within the housing can be used to engage and lift the cart such that the top of the support surface is adjacent to the second opening when the process of receiving the print media sheets is initiated. As the print media sheets are received and arranged in the stack, this elevator can further be used to lower the cart.

In any case, the support surface can comprise alternating first sections and second sections. The second sections can be fixed to the frame such that the second sections are immovable at the top of the support surface and the first sections can be moveable relative to the second sections. Specifically, the first sections can be movable between a first position comprising an uppermost position, which is top aligned with the second sections (i.e., a first position aligned with the second sections at the top of the support surface), and a second position, which is lower than the first position relative to the top of the support surface. During the process of receiving the print media sheets, the first sections can specifically be in the first position (i.e., top aligned with the second sections) such that the top of the support surface has a planar contour so as to provide essentially uniform support to the stack of print media sheets.

The method can further comprise manually moving the cart back out of the housing through the first opening and further moving the first sections to the second position (i.e., lower than the first position) such that the top of the support surface has a corrugated contour to facilitate transferring of the stack of print media sheets to an additional support surface. After transferring the stack of print media sheets, the cart can be manually moved back into the housing through the first opening and the first sections can be moved back into the first position in order to receive an additional print media sheets.

Various additional method steps are also disclosed for moving the first sections of the support surface to the first position, for holding the first sections of the support surface in the first position, for moving the first sections of the support surface to the second position and for moving the stacker cart back and forth between a sheet stack receiving and/or storing location within the stacker housing and a sheet stack transferring location.

DETAILED DESCRIPTION

Oftentimes, a stacker cart, which is used in conjunction with a sheet stacker in a printing system, will incorporate a ribbed support surface. Within the stacker, print media sheets are received and arranged in a stack on the ribbed support surface. The stack of print media sheets is stored on the ribbed support surface until a user is ready to move (e.g., roll, slide, etc.) the cart to a transfer location (i.e., an unload location). At the transfer location, the ribbed support surface is interdigitated with (i.e., intercalated with, mated with, etc.) a complementary ribbed support surface of, for example, another cart. Then, one or both of the ribbed support surfaces on the carts are moved along a vertical axis in order to separate the ribbed support surfaces such that the complementary ribbed support surface is the higher of the two and, thereby such that the stack is transferred to the complementary ribbed support surface. The stacker cart is then moved back into position within the stacker housing. Unfortunately, as mentioned above, the support provided by the ribbed support surface is non-uniform. Non-uniform support of a stack of print media sheets can lead to deformation (e.g., curling) of the sheets within the sheet stack and, particularly, deformation of the bottom sheets in a relatively large sheet stack and deformation of any sheets that are within a relatively small sheet stack and that have edges (e.g., trailing or leading edges) that land between ribs.

In view of the foregoing, disclosed herein is a cart having a support surface with a selectively adjustable contour for providing essentially uniform support to a load (e.g., a stack of print media sheets) during receiving and storing modes and for facilitating transfer of the load to another support surface during a transferring mode. Specifically, the cart can comprise a support surface with alternating fixed and movable sections. In the receiving and storage modes, the movable sections can be top aligned with the fixed sections so that the support surface has an essentially planar contour for providing essentially uniform support (e.g., to prevent deformation of print media sheets within a stack of print media sheets on the support surface). In the transferring mode, the movable sections can be dropped lower so that the support surface has a corrugated contour for facilitating transfer of the load (e.g., using an interdigitation technique). Also disclosed herein is a printing system sheet stacker that incorporates such a cart for receiving, storing and transferring of a stack of print media sheets as well as associated methods.

More particularly, referring toFIGS. 1 and 2in combination, disclosed herein is a cart100(i.e., a pushcart, a handcart, a dolly, etc.). The cart100can comprise a frame110and a support surface120connected to (i.e., mounted on) the frame110.

The support surface120can have a top that can receive, store and transfer (i.e., can be adapted to receive, store and transfer, can be configured to receive, store and transfer, can be used to receive, store and transfer, etc.) a load130(e.g., a stack of paper sheets, of other print media sheets or of other flexible sheets). The support surface120can comprise alternating first sections121(i.e., moveable sections) and second sections122(i.e., fixed sections).

The first sections121and second sections122can be elongated, rectangular-shaped, sections (also referred to herein as ribs or tines) with the first sections121being shorter than the second sections122(i.e., the first sections can have a first height and the second sections122can have a second height that is greater the first height). Additionally, the second sections122can be fixed and, more particularly, can be mounted directly to the frame110such that they remain in a fixed positioned relative to the frame110and the top of the support surface120(i.e., such that they are immovable relative to the frame and the top of the support surface120). The first sections121can be moveable relative to the second sections122and, more particularly, can be mounted such that they are moveable vertically (i.e., up or down) relative to the level of the second sections122. That is, the first sections121can be vertically movable between a first position, which is the uppermost position for the first sections121(i.e., the highest position possible) (seeFIG. 1) and a second position, which is a lower position (seeFIG. 2). In the first position as shown inFIG. 1the first sections121can be top aligned with the second sections122such that the top surfaces of the first sections121and top surfaces of the second sections122are aligned (i.e., are coplanar). That is, in the first position the first sections121can be aligned with the second sections122at the top of the support surface120. The second position as shown inFIG. 2can be lower than the first position. That is, in the second position the first sections121can be lower than the second sections122relative to the top of the support surface120. For example, in the second position, the first sections121can be bottom aligned with the second sections122such that the top surfaces of the first sections121are a specific distance123lower than the top surfaces of the second sections122(namely, a distance equal to the difference between the first height of the first sections121and the second height of the second sections).

Spacing between adjacent first sections121and second sections122should be only so wide as to allow unhindered (i.e., unobstructed, smooth, etc.) movement of the first sections121relative to the second sections122. For example, spacing between adjacent first sections121and second sections122should be less than a ½ inch and, preferably, less than ¼ inch. Thus, when the first sections121are in the first position as shown inFIG. 1, the top of the support surface120will have a planar contour so as to provide essentially uniform support to the load130(e.g., during load receiving and load storing modes). When the first sections121are in the second position as shown inFIG. 2, the top of the support surface120will have a corrugated contour so as to facilitate transferring of the load130to an additional support surface (see more detailed discussion below).

FIGS. 3A-3Care cross-section illustrations of an exemplary support surface120with the first sections121in the first position (i.e., top aligned with the second sections122), whereasFIGS. 4A-4Care cross-section illustrations of the same exemplary support surface120with the first sections121in the second position (i.e., dropped lower than the first position). Referring toFIGS. 3A-3Cand4A-4C in combination withFIGS. 1 and 2, this exemplary support surface120can be configured as follows to allow for movement of the first sections121between the first position and the second position.

Each second section122can comprise at least two essentially identical, vertically oriented, through-slots (e.g., see the first through-slot126aand the second through-slot126blocated at opposite ends of the second section122, as shown inFIGS. 1,2,3B and4B). Each through-slot126a,126bcan further extend through the entire width of the second section122. Each first section121can comprise at least two essentially identical through-holes (e.g., see the first through-hole127aand the second through-hole127blocated at opposite ends of the first section121, as shown in FIGS.3C and4C). Each through-hole127a,127bcan extend through the entire width of the first section121. All of the first through-holes127aand first through-slots126aat one end of the support surface120can be aligned and similarly all of the second through-holes127band second through-slots126bat the opposite end of the support surface120can be aligned. A first support bar125acan be thread through the aligned first through-holes127aand first through-slots126aand a second support bar125bcan be thread through the aligned second through-holes127band second through-slots126b.

In all of the first sections121, all of the through-holes127a,127bshould be approximately equal in size (e.g., equal in diameter) to the support bars125a,125bsuch that the support bars125a,125bcan be thread through the through-holes127a,127bbut cannot otherwise move within the through-holes127a,127b. Additionally, in all of the first sections121, the tops of all the through-holes should be a specific distance129from the corresponding top surfaces of the first sections121. Similarly, in all the second sections122, the top ends of all the through-slots126a,126bshould be this same specific distance129from the corresponding top surfaces of those second sections122. Additionally, in all of the second sections122, the lengths128of the through-slots126a,126bbetween the top end and the bottom end should be equal to the desired distance123between the top surfaces of adjacent first and second sections121,122when in the second position (i.e., the desired distance123for lowering the first sections121when moving from the first position to the second position). In this configuration, the first sections121can be simultaneous moved between the first position and second position and top alignment of the first sections121and second sections122is assured with the first sections121are moved into the first position.

As mentioned above, when the first sections121are in the second position as shown inFIG. 2, the top of the support surface120will have a corrugated contour so as to facilitate transferring of the load130to an additional support surface (see more detailed discussion below). Specifically, as shown inFIG. 7, the corrugated contour of the support surface120when the first sections121are in the second position (i.e., lower than the first position) allows for interdigitation (i.e., intercalation with, mating with, etc.) with a complementary support surface220(e.g., of another cart200, such as a truck-type or fork-type cart). That is, another cart200with a complementary support surface220having support sections221(also referred to herein as ribs or tines) can be mated with the support surface120of the cart100such that, as the carts100,200, are moved together the support sections221of the complementary support surface220of the cart200are moved into the spaces above the lowered first sections121and between the adjacent second sections122of the support surface120of the cart100. Then, the support surface120and/or the complementary support surface220can be moved along a vertical axis in order such that the complementary support surface220is the higher than the support surface120and, thereby such that the load130is transferred to the complementary support surface220.

It should be noted that the cart100can further comprise various other additional features that allow for moving and, particularly, lifting the first sections121of the support surface120to the first position, for holding the first sections121of the support surface120in the first position, and for moving and, particularly, lowering the first sections121of the support surface120to the second position.

For example, as shown inFIGS. 5A and 5B, the first and second through-slots126a,126bon the outermost second sections122can each further comprise top end horizontal extensions501configure to allow a user to: (1) manually slide the support bars125a,125bup to the top ends of the through-slots126a,126bsuch that the first sections121are in the first position and further over into the horizontal extensions501such that the first sections121are supported and held in the first position (seeFIG. 5A); and (2) manually slide the support bars125a,125bbe out of the horizontal extensions501so that they can drop to the bottom ends of the through-slots126a,126band, thereby moving the first sections121into the second position (seeFIG. 5B).

Alternatively, as shown inFIGS. 6A and 6B, one or more latches601can engage (i.e., can be adapted to engage, can be configured to engage, etc.) at least one of the first sections121so as to hold (i.e., maintain, lock, etc.) the first sections121in the first position. For example, the latch(es)601can comprise spring-loaded latches that automatically engage the first sections121to hold the first sections121in the first position when the first sections121are moved above the location of the latch(es)601to that first position (e.g., either manually or by an optional lift mechanism603, such as a lever, foot pedal or pushbutton actuated lift mechanism) (seeFIG. 6A). Such latch(es)601) can further be operably connected to a release or, more particularly, a release mechanism602(e.g., a lever, foot pedal or pushbutton actuated release mechanism). This release mechanism602can be actuatable (e.g., depressable in the case of a lever, foot pedal or pushbutton) to release the latch(es)601and, thereby to allow the first sections121to move (e.g., drop by force of gravity) back down to the second position (seeFIG. 6B). It should be noted that actuation of the release mechanism602can be manual (i.e., performed by the user). Alternatively, the release mechanism602can be configured and, particularly, can be positioned on the cart100such that as the carts100and200are brought together for transfer of the load130, the release mechanism602will automatically be triggered (e.g., depressed). It should further be noted that the optional lift mechanism603can be a discrete mechanism from the release mechanism602, as shown InFIGS. 6A and 6B. Alternatively, a more complex mechanism that combines both lift and release functions through the actuation of a lever, foot pedal or push button (e.g., by depressing a lever, foot pedal or push button a first time to lift the first sections121and, thereby engage the latch(es)601and by depressing a lever, foot pedal or push button a second time to release the latch(es)601). It should further be noted that many different mechanisms (e.g., spring loaded mechanisms, hydraulic mechanisms, etc.) suitable for lifting, holding, and/or lowering device components could alternatively be incorporated into the cart disclosed herein. Such mechanisms are well known in the art and, thus, the details are omitted from this specification in order to allow the reader to focus on the salient aspects of the cart as disclosed.

Referring again toFIGS. 1 and 2, other features of the cart100can include, but are not limited to, wheels170and a push handle160. The wheels170can be connected to the bottom surface113of the cart frame110relative to the top of the support surface120and can, for example, comprise conventional bi-directional type wheels (as shown) or caster type wheels. The push handle160can be connected to one end111of the cart frame110. Specifically, the push handle160can be fixed to one end111of the frame110(e.g., screwed, bolted or soldered). Alternatively, the push handle160can be detachably mounted to one end111of the frame110. For example, the push handle160can comprise a U-shaped handle with a center push bar161positioned laterally between two side rails162. The frame110can comprise pockets163(i.e., cups or channels) on opposite sides of one end111of the frame110for receiving the side rails162. The side rails162can be held in place in the pockets163, for example, by a conventional button latch164, which can be manually depressed in order to detach the push handle160. The combination of wheels170and push handle160allow the cart100to be manually moved and, particularly, rolled between load receiving, storing and transferring locations.

Referring toFIG. 8, also disclosed is a printing system sheet stacker800(i.e., a sheet stacker module (as shown) of a modular printing system or integrated sheet stacker in a non-modular printing system). This sheet stacker800can incorporate the cart100described in detail above and illustrated inFIGS. 1-7, as an integrated cart/stacker tray.

Specifically, the sheet stacker800can comprise a housing810, having a first opening811and a second opening812. The sheet stacker800can further comprise the cart100, which is manually movable (i.e., slidable, rollable, etc.) into and out of the housing810through the first opening811. The sheet stacker800can further receive (i.e., can be adapted to receive, can be configured to receive, etc.) print media sheets (e.g., paper sheets or other flexible print media sheets), which are output from the printing system, through the second opening812.

As described in detail above, the cart100can comprise a frame110and a support surface120connected to the frame110. The cart100can further comprise wheels170connected to a bottom surface of the frame110relative to the top of the support surface120and a push handle160connected to one end of the frame110in order to facilitate movement into and out of the housing810through the first opening811. Optionally, the handle160can be detachable in order to allow the cart100to be fully seated within the housing810(as shown inFIG. 9).

The support surface120of the cart100can have a top and can comprise alternating first sections121and second sections122. The second sections122can be fixed to the frame110such that the second sections122are immovable relative to the frame110and the top of the support surface. The first sections121can be shorter than and moveable relative to the second sections122. Specifically, the first sections121can be vertically movable between a first position, which is top aligned with the second sections122(i.e., between a first position aligned with the second sections122at the top of the support surface120) and which is the uppermost position for the first sections121(i.e., the highest position possible) and a second position, which is lower than the first position relative to the top of the support surface120(e.g., which is bottom aligned with the second sections122).

When cart100is within the housing810, as shown inFIG. 9, the first sections121can be held (i.e., locked) in the first position (i.e., top aligned with the second sections122) so that the top of the support surface120has a planar contour. The top of the support surface120can then receive the print media sheets, which are output from the printing system and enter the housing810through the second opening812. Optionally, the sheet stacker800can comprise an elevator820(i.e., elevator system) within the housing810. This elevator820can engage and lift (i.e., can be adapted to engage and lift, can be configured to engage and lift, etc.) the cart100such that the top of the support surface120is moved to a height adjacent to the second opening812when the process of receiving the print media sheets is initiated (seeFIG. 10). In any case, as the print media sheets enter the housing810through the second opening812and are received on the top of the support surface120, they are arranged in a stack1130(e.g., seeFIG. 11). It should be noted that the elevator820can further automatically lower (i.e., can be adapted to automatically lower, can be configured to automatically lower, etc.) the cart100as the print media sheets are received and arranged in the stack1130in order to accommodate the increasing stack height. Elevator systems for sheet stackers are well known in the art (e.g., see U.S. Patent Application Publication No. 20110260392 of Herrmann et. al, published on Oct. 27, 2011 and incorporated herein by reference) and, thus, the details of the elevator820are omitted from this specification in order to allow the reader to focus on the salient aspects of the disclosed sheet stacker.

Since the first sections121are in the first position (i.e., top aligned with the second sections122) when the print media sheets are received, the resulting planar contour of the top of the support surface120will provide essentially uniform support to the stack1130of print media sheets (e.g., during receiving and load storing modes) and, thereby will prevent deformation of the print media sheets within the stack1130. However, when the handle160is reattached (if applicable) and the cart100is moved back out of the housing810through the first opening811(as shown inFIG. 12) in order to transfer (i.e., unload) the stack1130of print media sheets onto another support surface, the first sections121can be moved to the second position (i.e., lower than the first position relative to the top of the support surface120) so that the top of the support surface120will have a corrugated contour in order to facilitate transferring of the stack1130(e.g., in the same manner as described in detail above and illustrated inFIG. 7).

It should be noted that, as described in detail above and illustrated inFIGS. 5A-5Band6A-6B, the cart100can comprise various other additional features that allow for moving and, particularly, lifting the first sections121of the support surface120to the first position, for holding the first sections121of the support surface120in the first position, and for moving and, particularly, lowering the first sections121of the support surface120to the second position. Such additional features would allow the raising and lowering of the first sections121at any time regardless of whether the cart100is within the housing810or outside the housing810. However, it should further be noted that, if the sheet stacker800comprises an elevator820and if a configuration similar to that shown inFIGS. 6A-6Bwith latch(es)601, which automatically holds the first sections121of the support surface120in place when moved to the first position, and a release mechanism602, which can be manually actuated to move the first sections121of the support surface120back to the second position, then in one embodiment the elevator820can automatically and simultaneously engage and lift (i.e., can be adapted to automatically and simultaneously engaged and lift, can be configured to automatically and simultaneously engage and lift, etc.) the first sections121as it engages and lifts the cart100itself. In this case, when the first sections121are moved by the elevator820above the location of the latch(es)601to that first position, the latch(es)601will automatically engage. By automatically and simultaneously moving the first sections121into the first position when the cart100is raised to receive print media sheets, the support surface will always present a planar contour as print media sheets are being stacked thereon.

Then, when the cart100is moved out of the housing810through the first opening811, the release mechanism602(e.g., a lever, a foot pedal, pushbutton, etc.) can be actuated (e.g., depressed in the case of a lever, foot pedal or pushbutton) to release the latch(es)601and, thereby allow the first sections121to move (e.g., drop by force of gravity) back down to the second position to facilitate transfer of the stack1130to another support surface. As discussed previously, actuation of the release mechanism602can be manual (i.e., performed by the user). Alternatively, the release mechanism602can be configured and, particularly, can be positioned on the cart100such that as the carts100and200are brought together for transfer of the load130, the release mechanism602will automatically be triggered (e.g., depressed).

Referring toFIG. 13, also disclosed herein is a method for using a cart100, as described in detail above and illustrated inFIGS. 1-2, to receive, store and transfer a load130(e.g., a stack of paper sheets, of other print media sheets or of other flexible sheets).

Specifically, the method can comprise providing a cart100, having a support surface120with a top and alternating first sections121and second sections122, where the first sections121are shorter and moveable relative to the second sections122(1302). Specifically, as discussed above, the second sections122can be fixed and, more particularly, can be mounted directly to the frame110such that they remain in a fixed positioned relative to the frame110and the top of the support surface120(i.e., such that they are immovable relative to the frame and the top of the support surface120). The first sections121can be moveable relative to the second sections122and, more particularly, can be mounted such that they are moveable vertically (i.e., up or down) relative to the level of the second sections122.

In the method, the first sections121of the cart100can be moved to a first position, top aligned with the second sections122such that the support surface120has a planar contour, as shown inFIG. 1(1304). That is, the first sections121can be moved to a first position that is aligned with the second sections122at the top of the support surface120. This first position can be the uppermost position achievable by the first sections121. Next, the method can comprise receiving the load130on the top of the support surface120of the cart100(1306).

During the process1306of receiving the load130as well as during subsequent storing of the load130, the first sections121can be held in the first position so that the planar contour of the top of the support surface120provides essentially uniform support to the load130.

It should be noted that the processes of moving the first sections121to and holding the first sections121in the first position will vary depending upon the configuration of the support surface120. For example, if, as shown inFIG. 5Aand described in detail above, the support surface120is configured such that the first and second through-slots126a,126bon the outermost second sections122each comprise top end horizontal extensions501, the support bars125a,125bcan be manually slid up to the first position at the top ends of the through-slots126a,126band, then, over into the horizontal extensions501in order to hold the first sections121in place in the first position. Alternatively, if, as shown inFIG. 6A, the support surface120is configured with one or more latches601, the first sections121can be manually moved to the first position or can be moved to the first position by an optional lift mechanism603and, once there, the latch(es)601can automatically engage and hold the first sections121in the first position. Thus, no additional method steps are required to hold the first sections121in place once the first sections121are moved into the first position.

After receiving and, if applicable, after any storage of the load130, the cart100can be moved to another location for transferring (i.e., off-loading) the load130(1308). Then, the first sections121can be moved to a second position that is lower than the first position relative to the top of the support surface120(e.g., that is bottom aligned with the second sections122) such that the top of the support surface120has a corrugated contour, as shown inFIG. 2(1310).

It should be noted that the process of moving the first sections121to the second position will also vary depending upon the configuration of the support surface120. For example, if, as shown inFIG. 5B, the support surface120is configured such that the first and second through-slots126a,126bon the outermost second sections122each comprise top end horizontal extensions501, the support bars125a,125bcan be manually slid out of the horizontal extensions501and allowed to drop down into the second position at bottom ends of the through-slots126a,126b. Alternatively, as shown inFIG. 6B, a release mechanism602(e.g., a lever, a foot pedal, pushbutton, etc.) operably connected to the latch(s)601can be actuated (e.g., depressed in the case of a lever, foot pedal or pushbutton) to release the latch(es)601and, thereby allow the first sections121to move (e.g., drop by force of gravity) back down to the second position. Actuation of the release mechanism602can be manual (i.e., performed by the user) or, alternatively, automatically triggered during transferring of the load130(as discussed below at process1312).

Once the first sections121are in the second position, the load130can be transferred to an additional support surface220, for example, of another cart200using an interdigitation technique (i.e., an intercalation technique, a mating technique, etc.), as shown inFIG. 7(1312). Specifically, as shown inFIG. 7, at process1312the corrugated contour of the top of the support surface120can be interdigitated with (i.e., intercalated with, mated with, etc.) a complementary support surface220(e.g., of another cart200, such as a truck-type or fork-type cart). That is, another cart200with a complementary support surface220having support sections221(also referred to herein as ribs or tines) can be mated with the support surface120of the cart100such that, as the carts100,200, are moved together the support sections221of the cart200are moved into the spaces above the lowered first sections121and between the adjacent second sections122of the support surface120of the cart100. Then, the support surface120and/or the complementary support surface220can be moved along a vertical axis in order such that the complementary support surface220is the higher than the support surface120and, thereby such that the load130is transferred to the complementary support surface220.

After transferring (i.e., unloading) the load130, the processes1304-1312can be iteratively repeated. That is, the first sections121can be moved back into the first position in order to receive an additional load (1304), a load can be received (1306) and so on.

Referring toFIG. 14, also disclosed is a method for using a cart100, as described in detail above and illustrated inFIGS. 1-2, as an integrated cart/stacker tray in the printing system sheet stacker800, as described in detail above and illustrated inFIG. 8, in order to receive, store and transfer a stack of print media sheets.

Specifically, the method can comprise providing a cart100, having a support surface120with a top and alternating first sections121and second sections122, where the first sections121are shorter than and moveable relative to the second sections122(1402). Specifically, as discussed above, the second sections122can be fixed and, more particularly, can be mounted directly to the frame110such that they remain in a fixed positioned relative to the frame110and the top of the support surface120(i.e., such that they are immovable relative to the frame and the top of the support surface120). The first sections121can be moveable relative to the second sections122and, more particularly, can be mounted such that they are moveable vertically (i.e., up or down) relative to the level of the second sections122.

In the method, this cart100can be manually moved (e.g., slid, rolled, etc.) into a housing810for a sheet stacker800through a first opening811(1404). Optionally, once in the housing810, the handle160of the cart can be detached in order to allow the cart100to be fully seated within the housing810(as shown inFIG. 9) (1406).

The first sections121of the cart100can be moved to a first position, top aligned with the second sections122such that the top of the support surface120has a planar contour, as shown inFIG. 9(1408). That is, the first sections121can be moved to a first position that is aligned with the second sections122at the top of the support surface120. This first position can be the uppermost position for the first sections121(i.e., the highest position possible).

Next, the method can comprise receiving, by the top of the support surface120, print media sheets, which are output by the printing system and enter the housing810through a second opening812(1410). Optionally, prior to receiving the print media sheets, an elevator820within the housing810can be used to engage and lift the cart100such that the top of the support surface120is moved to a height adjacent to the second opening812(1411, seeFIG. 10). In any case, as the print media sheets enter the housing810through the second opening812and are received on the top of the support surface120, they are arranged in a stack1130(seeFIG. 11). It should be noted that, during this process of receiving the print media sheets and arranging them in a stack1130, the elevator820can further be used to automatically lower the cart100in order to accommodate the increasing stack height. Additionally, during this process of receiving the print media sheets, the first sections121can be held in the first position so that the planar contour of the support surface120provide essentially uniform support to the stack1130.

It should be noted that the processes of moving the first sections121to and holding the first sections121in the first position will vary depending upon the configuration of the support surface120. For example, if, as shown inFIG. 5Aand described in detail above, the support surface120is configured such that the first and second through-slots126a,126bon the outermost second sections122each comprise top end horizontal extensions501, the support bars125a,125bcan be manually slid up to the first position at the top ends of the through-slots126a,126band, then, over into the horizontal extensions501in order to hold the first sections121in place in the first position. Alternatively, if, as shown inFIG. 6A, the support surface120is configured with one or more latches601, the first sections121can be manually moved to the first position or can be moved to the first position by an optional lift mechanism603and, once there, the latch(es)601can automatically engage and hold the first sections121in the first position. In one particular embodiment, instead of moving the first sections121to the first position manually or by using a lift mechanism603, the elevator820, which is used to engage and lift the cart at process1411, can automatically and simultaneously be used to also engage and lift the first sections121to the first position at which time the latch(es)601will automatically engage to hold the first sections121in place. By using the elevator820to automatically and simultaneously moving the first sections121into the first position when the cart100is raised to receive print media sheets, the support surface120will always present a planar contour as print media sheets are being stacked thereon.

After receiving the print media sheets and arranging them in a stack1130and, if applicable, after any storage of the stack1130, the cart100can be moved out of the housing810to another location for transferring (i.e., off-loading) the stack, as shown inFIG. 12(1412). Then, the first sections121can be moved to a second position that is lower than the first position relative to the top of the support surface (e.g., that is bottom aligned with the second sections122) such that the top of the support surface120has a corrugated contour, as shown inFIG. 2(1414).

It should be noted that the process of moving the first sections121to the second position will vary depending upon the configuration of the support surface120. For example, if, as shown inFIG. 5B, the support surface120is configured such that the first and second through-slots126a,126bon the outermost second sections122each comprise top end horizontal extensions501, the support bars125a,125bcan be manually slid out of the horizontal extensions501and allowed to drop down into the second position at bottom ends of the through-slots126a,126b. Alternatively, as shownFIG. 6B, a release mechanism602(e.g., a lever, a foot pedal, pushbutton, etc.) operably connected to the latch(s)601can be actuated (e.g., depressed in the case of a lever, foot pedal or pushbutton) to release the latch(es)601and, thereby allow the first sections121to move (e.g., drop by force of gravity) back down to the second position (seeFIG. 6B). Actuation of the release mechanism602can be manual (i.e., performed by the user) or, alternatively, automatically triggered during transferring of the stack of print media sheets1130(as discussed below at process1416).

Once the first sections121are in the second position, the stack1130can be transferred to an additional support surface220, for example, of another cart200using an interdigitation technique (i.e., an intercalation technique, a mating technique, etc.), as shown inFIG. 7(1416). Specifically, as shown inFIG. 7, at process1416the corrugated contour of the top of the support surface120can be interdigitated with (i.e., intercalated with, mated with, etc.) a complementary support surface220(e.g., of another cart200, such as a truck-type or fork-type cart). That is, another cart200with a complementary support surface220having support sections221(also referred to herein as ribs or tines) can be mated with the support surface120of the cart100such that, as the carts100,200, are moved together the support sections221of the complementary support surface220on the cart200are moved into the spaces above the lowered first sections121and between the adjacent second sections122of the support surface120of the cart100. Then, the support surface120and/or the complementary support surface220can be moved along a vertical axis in order such that the complementary support surface220is the higher than the support surface120and, thereby such that the stack1130is transferred to the complementary support surface220.

After transferring (i.e., unloading) the stack1130, the processes1404-1416can be iteratively repeated. That is, the cart100can be moved (e.g., rolled, slid, etc.) back into the housing first sections121(1404), the cart handle160can be detached (1406), etc.

As mentioned above, the apparatuses (e.g., the cart100and sheet stacker800, which incorporates such a cart100) as well as the methods of operating these apparatuses disclosed herein can be used in conjunction with a printing system.FIG. 15illustrates on such printing system1500. This printing system1500can comprise, for example, a printer, copier, multi-function machine, multi-function device (MFD), etc. The printing system1500can comprise a computerized printing device1504that includes a controller/processor1524and a communications port (input/output)1526operatively connected to the processor1524and to a computerized network1502external to the printing device1504. Also, the computerized printing device1504can include at least one accessory functional component, such as a graphic user interface assembly1536that also operate on the power supplied from the external power source1528(through the power supply1522).

The input/output device1526is used for communications to and from the computerized printing device1504. The processor1524controls the various actions of the computerized device. A non-transitory computer storage medium device1520(which can be optical, magnetic, capacitor based, etc.) is readable by the processor1524and stores instructions that the processor1524executes to allow the printing device to perform its various functions, such as those described herein. Thus, as shown inFIG. 15, a housing for the printing device1504contains one or more functional components that operate on power supplied from the alternating current (AC)1528by the power supply1522. The power supply1522can comprise a power storage element (e.g., a battery), connects to an external alternating current power source1528and converts the external power into the type of power needed by the various components.

The computerized printing device1504also includes at least one marking device (printing engines)1510operatively connected to the processor1524, a media path1516positioned to supply sheets of media from a sheet supply1514to the marking device(s)510, etc. After receiving various markings from the printing engine(s), the sheets of print media can pass to a sheet stacker800, as described in detail above and illustrated inFIG. 8, that receives and stacks the print media sheets onto the support surface120of a cart, such as that described in detail above and illustrated inFIGS. 1-2. Also, the computerized printing device1504can include at least one accessory functional component (such as a scanner/document handler1512, etc.) that also operate on the power supplied from the external power source1528(through the power supply1522).

Further, items1502represent the media processing components, which can, for example, change the size or shape of the media, form openings in the media, change the uniform background color of the media, etc. The physical media trays1514maintain unaltered media, and such unaltered media is supplied to the printing engine1510for printing operations. The media processing components1502have elements that physically alter the unaltered media. The processor1524maintains the status of unaltered media currently available within the physical media trays1514, and the processor1524also maintains the status of currently available media processing components1502of the media processing components1502.

The terms printer or printing device as used herein encompasses any apparatus, such as a digital copier, bookmaking machine, facsimile machine, multi-function machine, etc., which performs a print outputting function for any purpose. The details of printers, printing engines, etc., are well known by those ordinarily skilled in the art and are discussed in, for example, U.S. Pat. Nos. 6,032,004, and 7,874,664 the complete disclosures of which are fully incorporated herein by reference. The embodiments herein can encompass embodiments that print in color, monochrome, or handle color or monochrome image data. All foregoing embodiments are specifically applicable to electrostatographic and/or xerographic machines and/or processes.

Therefore, disclosed above is a cart having a support surface with a selectively adjustable contour for providing essentially uniform support to a load (e.g., a stack of print media sheets) during receiving and storing modes and for facilitating transfer of the load to another support surface during a transferring mode. Specifically, the cart can comprise a support surface with alternating fixed and movable sections. In the receiving and storage modes, the movable sections can be top aligned with the fixed sections so that the support surface has an essentially planar contour for providing essentially uniform support (e.g., to prevent deformation of print media sheets within a stack of print media sheets on the support surface). In the transferring mode, the movable sections can be dropped lower so that the support surface has a corrugated contour for facilitating transfer of the load (e.g., using an interdigitation technique). Also disclosed herein is a printing system sheet stacker that incorporates such a cart for receiving, storing and transferring of a stack of print media sheets as well as associated methods.