Abstract:
In a printer having an input tray, a media loader insert is provided, the media loader insert including an insert body which defines a reduced-size media receptacle, the insert body being sized to securely fit within the input tray; and a width adjuster adjacent the reduced-size media receptacle, the width adjuster being positioned centrally along a side edge of the reduced-size media receptacle to centrally engage a side edge of media within the reduced-size media receptacle, thereby reducing media skew.

Description:
CROSS-REFERENCE TO RELATED APPLICATION  
       [0001]    This is a continuation of copending application Ser. No. 09/666,252 filed on Sep. 21, 2000, which is hereby incorporated by reference. 
     
    
     
       BACKGROUND  
         [0002]    Although printers typically are used to print on media of various media sizes, most printers have a maximum media width capacity, and correspondingly, a minimum media width on which effective printing can be accomplished. Some printers, such as high speed laser printers, provide dedicated input media trays for each media size. Lower cost printers, such as mass-market inkjet printers, generally have only one tray, typically accommodating letter-size media (8.5″×11″), with some adaptability to accommodate printing on media of different sizes.  
           [0003]    In order to accommodate printing on media of different width media, printers often employ adjustable media edge stops that slide to constrain the side edges of narrower media sheets. Printing on media shorter than standard letter-size length normally is accommodated by feeding a stack of the shorter media into an input tray until its leading edge abuts a stop. While this has proven workable in some instances to accommodate envelopes and smaller index cards, there have been disadvantages to this approach.  
           [0004]    Some printers, for example, have input trays that are not removable, and which extend well into the body of the printer. This leaves a significant distance between the media insertion aperture and the leading edge stop. It thus may be difficult to load or extract media which is shorter than this distance. Furthermore, it may be difficult to adjust the media edge stop in a manner necessary to maintain the media in its proper lateral position.  
           [0005]    A further difficulty in accommodating smaller media sizes is that many printers rely on a common media registration scheme, such as using one edge of a media tray as a fixed side edge reference for all media sizes. Any measures to accommodate smaller media that do not provide contact with this reference surface will require printer firmware changes, generating cost and complexity disadvantages.  
           [0006]    Additionally, even printers which do overcome problems with loading smaller media may not be adequately adjustable in width, leading to problems of unacceptable media skew. For example, media edge stops typically are adapted to engage a central region of standard size media sheets, laterally biasing the media in order to maintain proper input stack orientation. It will be appreciated, however, that smaller media typically is engaged nearer a trailing end of the media, potentially skewing the media as it enters the insertion aperture. This may be exacerbated as the input tray floor pivots upward, making it difficult to maintain a lateral biasing force on the input media stack. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]    [0007]FIG. 1 is an isometric view of a media loader insert constructed in accordance with an embodiment of the present invention, a small-size media stack being shown in dashed lines.  
         [0008]    [0008]FIG. 2 is a plan view of the media loader insert of FIG. 1, the media loader insert having been inserted into a printer input tray in accordance with an embodiment of the present invention.  
         [0009]    [0009]FIG. 3 is a sectional side view of the media loader insert and input tray of FIG. 2, the input tray having been inserted into a printer to demonstrate operation of the input tray. 
     
    
     DETAILED DESCRIPTION  
       [0010]    Referring to FIGS. 1 through 3, a media loader insert  10  is shown, such media loader insert being configured to accommodate receipt of small-size media for printing. Accordingly, the media loader insert includes a generally rectangular, planar body  12  with a media receptacle  14  sized to receive a small-size media stack  20  (typically A6 media or Hagaki media) such that small-size media sheets may be automatically fed or picked, through a printer&#39;s input port. The media holder is adapted to maintain the media sheets in the depicted stacked relationship so as to reduce difficulties typically associated with the input of small-size media, namely media skew.  
         [0011]    As indicated in FIG. 2, media loader insert  10  is configured for fitted placement in a printer&#39;s input tray  110 , the media loader insert typically being characterized by a profile which corresponds that of the input tray. It will be appreciated, for example, that body  12  has a width which corresponds to the width of letter-size paper, a length which corresponds somewhat to the length of letter-size paper, and a depth which corresponds somewhat to the depth of the input tray. In fact, body  12  has a rear edge  12   a  which mimics the contour of the input tray&#39;s rear edge  112  so as to provide a visual cue to aid in alignment of media loader  10  within input tray  110 .  
         [0012]    Upon placement of the media loader insert in input tray  110 , the input tray&#39;s side edge stop  130  is adjusted to engage a side edge of the media loader insert in a manner similar to the manner in which the side stop would engage the side edge of a letter-size media stack. This typically means that the side edge stop will engage a central region of the media loader insert&#39;s side edge. This is in contrast to the rearward region of the small-size media stack which would be engaged by the input tray&#39;s side edge stop if the media was placed directly in the input tray. Side edge stop  130  may be spring-biased toward engagement with media loader insert  10 , thus urging the media loader insert into engagement with the opposite side edge of the input tray, and into a desired, non-skewed orientation. Alternatively, the side edge stop may be manually adjusted, and held in position adjacent the media loader insert via another suitable journaling mechanism.  
         [0013]    Similarly, the input tray&#39;s rear edge stop  140  may be configurable to engage a rear edge of the media loader input in a manner similar to the manner in which the rear edge stop would engage a letter-size media stack. Typically, the rear edge stop will be manually adjusted, and held in position adjacent the media loader insert via a suitable journaling mechanism.  
         [0014]    The media loader insert is placed in the input tray using a recessed handle  16 , which also typically is formed in body  12 . As will be appreciated upon reading further, the media loader insert is intended to receive media after placement of the media loader insert in the input tray, the input tray serving to define the remaining retention boundaries for the small-size media stack. The media stack thus is closely held in a predetermined feed orientation, which orientation is selected to prevent media skew.  
         [0015]    For the purpose of simplifying this disclosure, FIG. 1 includes an illustration of orthogonal axes, such axes being useful in describing use of the depicted media loader insert. The indicated X axis corresponds to the media feed direction, the positive direction being “forward” or “downstream” in the direction of media feed. The Y axis corresponds to media width, the positive direction being toward the “right” as viewed from the leading edge of the media in the orientation depicted in FIG. 1. The Z axis corresponds to media stack height and is perpendicular to the plane of media, with the positive direction being “up” from the media stack in the orientation depicted in FIG. 1.  
         [0016]    Referring now to FIGS. 1 and 2, it will be appreciated that media loader insert  10  is adaptable to accommodate variations in media size, though such variations typically are relatively small, on the order of approximately 5-mm. The media loader insert thus includes a width adjuster  30 , which adjusts the position of a media-engaging surface  32 , and a length adjuster  40 , which adjusts the position of a media-engaging surface  42 . Width adjuster  30  engages a right-side edge of the small-size media stack, and thus includes a media-engaging surface  32  which extends generally parallel to the X axis. Length adjuster  40  engages a forward edge of the small-size media stack, and thus includes a media-engaging surface  42  which extends generally parallel to the Y axis.  
         [0017]    Media-engaging surface  32  is contoured to accommodate contact between the media-engaging surface and the side edge of the small-size media stack. Preferably, media-engaging surface  32  will engage a central region of the side edge of small-size media stack  20 , thus reducing the potential for undesirable media skew. The small-size media stack is further supported in the aforementioned central region by an adjustable floor  34 , which extends somewhat normally from media-engaging surface  32  to support the small-size media stack from below. It will be appreciated that adjustable floor  34  need not extend entirely across the media, but rather may support only a portion thereof.  
         [0018]    As indicated, width adjuster  30  is pivotal about a vertical axis A which extends parallel to the Z axis depicted in FIG. 1. Media-engaging surface  32  thus is pivotally adjustable along the Y axis to ensure contact between media-engaging surface  32  and the side edge of small-size media stack  20 . In the depicted embodiment, media-engaging surface  32  adjusts approximately 5-mm in the area which contacts the small-size media stack. Typically, media-engaging surface  32  is spring-biased in the negative Y direction, toward engagement with the small-size media stack via hinge assembly  36 . Such spring bias assists in maintaining proper media orientation, and thus in reducing media skew.  
         [0019]    In the present embodiment, width adjuster  30  also is pivotally adjustable about a horizontal axis B which extends parallel to the Y axis. Axis B, it will be noted, extends generally along a rearward end of the width adjuster to provide for pivotal adjustment of adjustable floor  34 . Floor  34  adjusts approximately 15-mm vertically adjacent the forward end thereof. By providing for such pivotal adjustment, it is possible to keep the width adjuster engaged with the side edge of the media stack while the elevation of the media stack is changed. It also is possible to engage the small-size media stack nearer to the forward edge of the media without affecting support of the media by the input tray, and thus without compromising normal media feed as demonstrated in FIG. 3. Floor  34  also may be spring-biased in the positive Z direction, toward engagement with the small-size media stack via hinge assembly  36 .  
         [0020]    Referring still to FIGS. 1 and 2, it will be noted that length adjuster  40  employs a generally planar media-engaging surface  42 . Preferably, media-engaging surface  42  engages a substantial portion of the rearward edge of small-size media stack  20 , typically in a central region thereof so as to reduce the potential for undesirable media skew. The small-size media stack is further supported along its rearward edge by a floor  44 , which extends somewhat normally from media-engaging surface  42  to support the small-size media stack from below. It will be appreciated that floor  44  need not extend entirely across the media, but does extend entirely across the media in the depicted embodiment. Floor  44  also extends approximately ¼ to % of the length of the media, as shown.  
         [0021]    As will be appreciated from review of the drawings, length adjuster  40  is linearly adjustable along the X axis to accommodate variations in the size of media used. The length adjuster thus includes a glide element  46  which travels along a track defined by tabs  46   a . The length adjuster is configured to travel a distance L, which typically is on the order of approximately 5-mm.  
         [0022]    In the depicted embodiment, the length adjuster is manually adjusted using a hand grip  48  which is located near the rearward end of the media loader, thus providing ready access to the user. The length adjuster maintains its selected position due to frictional forces between glide element  46  and track  46   a . Alternatively, media-engaging surface  42  may be biased in the positive X direction, toward engagement with the small-size media stack to assist in maintaining proper media alignment. A recess  49  provides the user with access to the media stack when inserting/removing media from the modified input tray.  
         [0023]    Accordingly, it will be appreciated that media loader insert  10  fits within input tray  110  to define a modified media receptacle space which is specially configured to receive small-size media. Media-engaging surface  32  is adjustable relative to the input tray&#39;s left side to define the width of the modified media receptacle space. Media-engaging surface  42  is adjustable relative to the input tray&#39;s front edge to define the length of the modified media receptacle space. The left and forward walls of input tray  110  respectively define fixed left and forward limits of the modified media receptacle space. Media within the modified media receptacle space is supported from below by width adjuster floor  34  and length adjuster floor  44 . A media elevator  120 , in turn, supports width adjuster floor  34  and provides supplemental support for the media stack (FIG. 3).  
         [0024]    Referring now to FIGS. 1 through 3, it will be noted that media loader insert  10  includes registration ridges  50  which extend upwardly from opposite sides of body  12  for use in registering the media loader insert within printer  210 . The media loader insert, it will be recalled, is inserted into input tray  110 , which is configured for placement in the printer&#39;s input tray registration channel  212 . The input tray also may be fitted with registration ridges, or other fitment mechanism as will be appreciated by those skilled in the field of printer design. As indicated above, the media loader insert is fixed within the input tray using adjustable side edge stop  130 , and using adjustable rear edge stop  140 . In fact, in the present embodiment, the length adjuster is cooperatively linked with the rear edge stop to accommodate adjustment of the rear edge stop.  
         [0025]    As indicated in FIG. 3, the registration ridges are elongate, generally planar projections oriented parallel to the X axis. Each ridge extends toward the back of the media loader insert from a central position just rearward of the media-engaging surface  42 . In the depicted embodiment, the ridge has a gently sloped leading ramp portion configured to engage registration channel  212  upon placement of the input tray within an input-tray-receiving aperture of printer  210 . With the ridges so received, the media loader insert is held in place along the Z axis. Furthermore, in addition to being constrained against lateral movement by the input tray&#39;s side edge stop, it is constrained against yaw misalignment by contact between the ridges and the registration channel.  
         [0026]    [0026]FIG. 3 also shows how media loader insert  10  rests on input tray floor  115 . The lower surface of length adjuster floor  44 , for example, directly contacts the upper surface of input tray floor  115 . The side walls of the media loader insert also typically rest on the input tray floor, creating a stable support structure. Length adjuster floor  44  is relatively thin, and thus supports small-size media stack  20  at a level only slightly above input tray floor  115 , preserving much of the capacity of the input tray.  
         [0027]    As will be noted, media  20  extends beyond the forward end of length adjuster floor  44 , typically onto width adjuster floor  34 , which is supported by a media elevator  120 . Elevator  120 , it will be understood, is formed within input tray  110  to selectively raise the leading edge of a media stack within the input tray into contact with a pick roller  215 . The media loader insert is adapted to utilize the media elevator by placing the leading edge of the small-size media onto the media elevator as shown. Pick roller  215  thus may be used to pull the media into the printer&#39;s input port  220  for printing.  
         [0028]    In the depicted embodiment, media elevator  120  is pivotally hinged to the input tray floor, the media elevator thus being capable of pivot about an axis C, which is generally parallel to the Y axis. Preferably, the media elevator will pivot cooperatively with width adjuster floor  34 , which rests on the media elevator and pivots about an axis B, also generally parallel to the Y axis. Typically, the media elevator is spring-biased to pivot upward (clockwise in FIG. 3) to urge media toward pick roller  215 . Although a single pick roller is shown, those skilled will understand that multiple, closely-spaced pick rollers may be used to further reduce the risk of media skew.  
         [0029]    Therefore, a user may employ the depicted media loader insert to reduce skew when printing on small-size media such as A6 media, Hagaki media, or the like. The user simply pulls out the input tray, removes any media from the input tray and places media loader insert  10  within the input tray. Media loader  10  then is secured in place using the input tray&#39;s adjustable side edge stop and adjustable rear edge stop as described above. The media loader insert may be positioned using matching rear contours of the media loader and the input tray. Upon securing the media holder insert in place, small-size media may be placed in recessed media support region  14 . The media is maintained in its proper orientation using width adjuster  30  and length adjuster  40 . Finally, the input tray may be re-inserted into the registration channel of the printer such that media may be picked from the media loader insert within the input tray.  
         [0030]    While the present embodiment has been shown and described with reference to the foregoing operational principles, it will be apparent to those skilled in the art that other changes in form and detail may be made without departing from the spirit and scope defined in the appended claims.