# Patent

## Title
Thermal printer having real-time force feedback on printhead pressure and method of using same

## Abstract

A thermal printer having a printhead, a printhead arm to engage and disengage the printhead, a platen roller, a user interface, and a printhead pressure adjustment mechanism is provided. The improvement consists of at least one force sensor adapted to sense the pressure between the printhead and the platen roller in real-time. The force sensor is communicatively linked to the user interface. The user interface is configured to display the pressure measured by the force sensor in real-time.

## Background
FIELD OF THE INVENTION
The present invention relates generally to thermal printers and in particular to measuring and displaying the pressure between the printhead and the platen roller.
BACKGROUND
Generally speaking in a thermal printer, the pressure between the printhead and the platen roller is a critical parameter that affects print quality, media movement, and the long-term performance of the printer. On many thermal printers, the printhead pressure may be manually adjusted.
Increasing the printhead pressure increases print quality contrast, increases the grip the roller has on the print media and thus the system torque load to the motor, may increase the possibility of motor stall, and if increased too much, will introduce smearing.
On the other hand, reducing printhead pressure will decrease print quality contrast; will decrease the grip the roller has on the print media and the system torque, which may cause the media to slip; and will reduce the likelihood of motor stall.
It can therefore be seen that correctly balanced printhead pressure is of utmost importance. As stated hereinbefore, allow a user to manually adjust the printhead pressure. However, the manual adjustment does not have feedback to the user on the printhead pressure thus adjusted.
Therefore, a need exists for printhead pressure feedback when a user adjusts the printhead pressure on a thermal printer.
SUMMARY
Accordingly, in one aspect, the present invention embraces an improved thermal printer having a printhead, a printhead arm to engage and disengage the printhead, a platen roller, a user interface; and a printhead pressure adjustment mechanism.
In an exemplary embodiment, the improvement comprises: at least one force sensor. The force sensor is adapted to sense the pressure between the printhead and the platen roller in real-time. The force sensor is communicatively linked to the user interface. The user interface is configured to display the pressure measured by the force sensor in real-time.
In another exemplary embodiment, the force sensor is mounted on the printhead arm. The pressure between the printhead and the platen roller is translated to the printhead arm.
In another exemplary embodiment, the force sensor is comprised of two force sensors. The two force sensors are integrated with each other. The integrated force sensors are mounted on the printhead.
In yet another exemplary embodiment, the thermal printer includes a processor and an Analog to Digital Conversion (ADC) unit. The ADC unit and the processor are communicatively linked and are intermediate the link from the force sensor to the user interface. The force sensor is configured to output an analog voltage proportional to the pressure at the printhead. The ADC is configured to convert the force sensor output to digital information and output the digital information to the processor. The processor is configured to translate the digital information into force units and to display the force units on the user interface.
In another exemplary embodiment of the thermal printer, the user interface is configured to display the pressure at the printhead in force units.
In another exemplary embodiment of the thermal printer, the printhead pressure adjustment mechanism is a manual adjustment mechanism. A user of the thermal printer can adjust the printhead pressure with the adjustment mechanism in conjunction with referencing the printhead pressure displayed on the user interface.
In yet another exemplary embodiment, the thermal printer comprises a printhead, a platen roller, a printhead pressure adjustment mechanism, and a first force sensor to measure the pressure between the printhead and the platen roller. A user interface may be configured to display the pressure measured by the first force sensor. The pressure is preferably measured in real time.
In another exemplary embodiment, the first force sensor is mounted on a printhead arm connected to the printhead. The pressure between the printhead and the platen roller is communicated to the printhead arm. The printhead arm moves the printhead relative to the platen roller.
In another exemplary embodiment, the thermal printer further comprises a second force sensor integrated with the first sensor. The integrated first and second force sensors are mounted on the printhead.
In another exemplary embodiment, the thermal printer further comprises a processor configured to proportionally adjust the digital information into force units reflecting the pressure between the printhead and the platen roller.
In another aspect, the present invention embraces a method of adjusting the printhead pressure on a thermal printer having a printhead, a printhead arm to engage and disengage the printhead, a platen roller, a user interface, and a printhead pressure adjustment mechanism.
In an exemplary embodiment, the method comprises the steps of: sensing the printhead pressure in real-time by a force sensor; communicating the printhead pressure to the user interface; displaying the printhead pressure on the user interface in real-time; and adjusting the printhead pressure based upon the real-time printhead pressure displayed on the user interface.
In another exemplary embodiment, the method comprises the steps of: sensing the printhead pressure with a first a force sensor; communicating the printhead pressure to the user interface; displaying the printhead pressure on the user interface; and adjusting the printhead pressure based upon the printhead pressure displayed on the user interface.
In another exemplary embodiment of the method, the communicating step is comprised of the steps of: outputting an analog voltage proportional to the pressure sensed in the sensing step from the force sensor to an ADC unit; converting the analog voltage to a digital signal by the ADC; outputting the digital signal to a processor; translating the digital signal to force units by the processor; and outputting the force units to the user interface for display in the displaying step.
In another exemplary embodiment of the method, the adjusting step is done manually by a user of the thermal printer.
In yet another exemplary embodiment of the method, the force sensor is mounted on the printhead arm.
In another exemplary embodiment of the method, the force sensor is comprised of at least two integrated force sensors. The integrated force sensors are mounted on the printhead.
In another exemplary embodiment of the method, the step of displaying the printhead pressure on the user interface includes displaying the printhead pressure in force units.
In another exemplary embodiment of the method, the adjusting step is accomplished manually by a user of the thermal printer. The adjusting step includes the user referencing the printhead pressure displayed on the user interface in the displaying step.
In another aspect, the present invention embraces an improved thermal printer having a printhead, a printhead arm to engage and disengage the printhead, a platen roller, a user interface, and a printhead pressure adjustment mechanism.
In an exemplary embodiment, the improvement comprises: at least one force sensor, a processor, and an ADC unit. The force sensor is adapted to sense the pressure between the printhead and the platen roller in real-time. The force sensor is communicatively linked to the user interface. The ADC and the processor are communicatively linked and are linked to the force sensor and to the user interface. The processor and the ADC are intermediate the link from the force sensor to the user interface. The force sensor is configured to output an analog voltage proportional to the pressure at the printhead. The ADC is configured to convert the force sensor output to digital information and output the digital information to the processor. The processor is configured to translate the digital information into force units and to send the force units to the user interface. The user interface is configured to display the force units from the processor in real-time.
In another exemplary embodiment, the force sensor is mounted on the printhead arm. The pressure between the printhead and the platen roller is translated to the printhead arm.
In another exemplary embodiment, the pressure sensed by the force sensor at the printhead arm is proportional to the pressure between the printhead and the platen roller.
In yet another exemplary embodiment, the processor is configured to proportionally adjust the digital information into force units reflecting the pressure between the printhead and the platen roller.
In another exemplary embodiment, the force sensor is comprised of two force sensors. The two force sensors are integrated. The integrated force sensors are mounted on the printhead.
In another exemplary embodiment, the user interface is configured to display the pressure at the printhead in force units.
In another exemplary embodiment, the printhead pressure adjustment mechanism is a manual adjustment mechanism. A user of the thermal printer can adjust the printhead pressure with the adjustment mechanism in conjunction with referencing the printhead pressure displayed on the user interface.
The foregoing illustrative summary, as well as other exemplary objectives and/or advantages of the invention, and the manner in which the same are accomplished, are further explained within the following detailed description and its accompanying drawings.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 schematically depicts a perspective view of an exemplary embodiment of the improved thermal printer in accordance with the present invention.
FIG. 2 schematically depicts a perspective view of another exemplary embodiment of the improved thermal printer image in accordance with the present invention.
FIG. 3 graphically depicts the operation of the force sensor and display of the sensed force in accordance with an exemplary embodiment of the present invention.
FIG. 4 graphically depicts in a flow chart a method of adjusting the printhead pressure on a thermal printer in an exemplary embodiment of the present invention.



DETAILED DESCRIPTION
The present invention embraces an improved thermal printer.
Referring now to FIG. 1, the thermal printer (200) has a printhead (210), a printhead arm (250) to engage and disengage the printhead (210), a platen roller (220), a user interface (230), and a printhead pressure adjustment mechanism (240). The printing ribbon is not installed on the thermal printer (200) in the figure for clarity.
In an exemplary embodiment, the improved thermal printer has at least one force sensor. The force sensor is adapted to sense the pressure between the printhead and the platen roller in real-time. In the present FIG. 1, the force sensor (260) is located on the printhead arm (250). The force sensor (260) is communicatively linked (link not shown) to the user interface (230). The pressure between the printhead (210) and the platen roller (220) is translated to the printhead arm (250) and therefore to the force sensor (260). The printhead arm (250) is pivotable to affect the printing. Due to the pivoting point nature of printhead arm (250), the actual force at the printhead (210) may not be exactly the same as the force feedback from force sensor (260) located on the printhead arm (250). However, the force sensed by the force sensor (260) at the printhead arm (250) is directly related to the force experience at the printhead (210).
Further, the user interface (230) is configured to display the pressure measured by the force sensor (260) in real-time.
Continuing to refer to FIG. 1 and in conjunction with FIG. 3, in another exemplary embodiment, the improved thermal printer (200) includes a processor (320) and an ADC unit (310). The processor and the ADC unit are communicatively linked and are intermediate the link from the force sensor (260) to the user interface (230). The force sensor (260) is configured to output an analog voltage (300) proportional to the pressure at the printhead (210). The ADC unit (310) is configured to convert the force sensor (260) output to digital information and output the digital information to the processor (320). The processor (320) is configured to translate the digital information into force units and to display the force units on the user interface (230).
As discussed hereinbefore, due to the pivoting point nature of printhead arm (250), the actual force at the printhead (210) may not be exactly the same as the force feedback from force sensor (260) located on the printhead arm (250). The processor (320) will be programmed with the relationship between the pressure experienced at the printhead (210) and that experienced by the force sensor (260) at the printhead arm (250). The processor will therefore convert the force reported by the force sensor (260) to the actual force at the printhead (210), and cause this to be displayed on the user interface (230).
Referring now to FIG. 2, in another exemplary embodiment, the thermal printer (200) is provided with force sensors (270a) and (270b). The force sensors (270a) and (270b) are integrated. The force sensors (270a) and (270b) are mounted on the printhead (210). The forces experienced at the printhead (210) are sensed by the integrated force sensors (270a) and (270b) and are sent to the user interface (230) and displayed on the user interface (230) in real time.
In the present embodiment, the force sensors (270a) and (270b) are preferably integrated with the printhead assembly (290). The printhead assembly (290), without the integrated force sensors (270a) and (270b), is typically is a commercial product.
In another exemplary embodiment, the processing of the forces sensed at force sensors (270a) and (270b) may be accomplished as shown in FIG. 3 and as described hereinbefore in conjunction with FIG. 1.
In any of the foregoing embodiments, the force displayed on the user interface (230) is preferably in Newtons. It is to be noted that the force sensors (170a and 170b) actually measure a force and not pressure at the printhead (210). However, since the area the force is applied is fixed, the force is proportional to the pressure.
In an improved thermal printer of any of the foregoing embodiments, a user may adjust the printhead (210) pressure via the printhead pressure adjustment mechanism (240) while observing the force at the printhead (210) in real-time on the user interface (230).
The present invention also embraces a method of adjusting the printhead pressure on a thermal printer having a printhead, a printhead arm to engage and disengage the printhead, a platen roller, a user interface, and a printhead pressure adjustment mechanism.
In an exemplary embodiment, referring now to FIG. 4, the method (400) comprises the steps of: (410) sensing the printhead pressure in real-time by a force sensor; (420) communicating the printhead pressure to the user interface; (430) displaying the printhead pressure on the user interface in real-time; and (440) adjusting the printhead pressure based upon the real-time printhead pressure displayed on the user interface.
In another exemplary embodiment of the method (400), the communicating step (420) is comprised of the steps of: (450) outputting an analog voltage proportional to the pressure sensed in the sensing step from the force sensor to an ADC unit; (460) converting the analog voltage to a digital signal by the ADC; (470) outputting the digital signal to a processor; (480) translating the digital signal to force units by the processor; and (490) outputting the force units to the user interface for display in the displaying step (430).
As described hereinbefore in conjunction with FIGS. 1 and 2, the force sensor of the method (400) may be mounted on the printhead arm or consist of a pair of integrated force sensors mounted on the printhead.
In another exemplary embodiment of the method (400), the adjusting step (410) may be done manually be a user. The user can read the force at the printhead in real time on the user interface, thus being capable of making precise and accurate printhead pressure adjustments.
To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.

## Claims

1. A thermal printer, comprising:
a printhead;
a platen roller;
a printhead arm connected to the printhead and configured to move the printhead relative to the platen roller;
a printhead pressure adjustment mechanism; and
a first force sensor mounted on the printhead arm, the first force sensor configured to measure pressure between the printhead and the platen roller, the printhead arm further configured such that pressure between the printhead and the platen roller translates to the printhead arm.

2. The thermal printer of claim 1, comprising a user interface configured to display the pressure measured by the first force sensor.

3. The thermal printer of claim 2, wherein the pressure is measured and displayed in real time.

4. The thermal printer of claim 2, wherein the user interface is configured to display the pressure in force units.

5. The thermal printer of claim 1, comprising a second force sensor integrated with the first force sensor, wherein the second force sensor is mounted on the printhead.

6. The thermal printer of claim 1, wherein the printhead pressure adjustment mechanism comprises a manual adjustment mechanism.

7. The thermal printer of claim 1, wherein the pressure measured by the first force sensor at the printhead arm exhibits proportional correspondence to the pressure between the printhead and the platen roller.

8. The thermal printer of claim 1, further comprising a processor configured to convert the pressure between the printhead and the platen roller measured by the first force sensor into force units.

9. A method, comprising:
sensing a printhead pressure between a printhead and a platen roller with a first force sensor mounted on a printhead arm, the printhead arm connected to the printhead and configured to move the printhead relative to the platen roller, the printhead arm further configured such that pressure between the printhead and the platen roller translates to the printhead arm;
communicating the printhead pressure to a user interface;
displaying the printhead pressure on the user interface; and
adjusting the printhead pressure based upon the printhead pressure displayed on the user interface.

10. The method of claim 9, wherein adjusting the printhead pressure is performed manually by a user of the thermal printer.

11. The method of claim 9, further comprising sensing a printhead pressure between the printhead and the platen roller with a second force sensor mounted on the printhead.

12. The method of claim 9, wherein displaying the printhead pressure on the user interface comprises displaying the printhead pressure in force units.

13. The method of claim 9, wherein the printhead pressure is adjusted using a printhead pressure adjustment mechanism, the printhead pressure sensed and displayed in real time, the printhead pressure adjustment mechanism configured to allow a user to adjust the printhead pressure while viewing the pressure sensed by the force sensor on the user interface.

14. A thermal printer, comprising:
a printhead;
a platen roller;
a printhead arm connected to the printhead and configured to move the printhead relative to the platen roller;
a force sensor mounted on the printhead arm, the force sensor configured to measure pressure between the printhead and the platen roller, the printhead arm further configured such that pressure between the printhead and the platen roller translates to the printhead arm;
a user interface configured to display the pressure measured by the force sensor; and
a printhead pressure adjustment mechanism configured to allow a user to adjust the pressure between the printhead and the platen roller while viewing the pressure measured by the force sensor on the display, the pressure measured and displayed in real time.

15. The thermal printer of claim 14, wherein the user interface is configured to display the pressure in force units.

16. The thermal printer of claim 14, wherein the printhead pressure adjustment mechanism comprises a manual adjustment mechanism.

17. The thermal printer of claim 14, wherein the pressure measured by the force sensor mounted on the printhead arm exhibits proportional correspondence to the pressure between the printhead and the platen roller.

18. The thermal printer of claim 14, further comprising a processor configured to convert the pressure between the printhead and the platen roller measured by the first force sensor into force units.

19. The thermal printer of claim 14, further comprising a second force sensor mounted on the printhead, the second force sensor integrated with the force sensor mounted on the printhead arm.