Abstract:
An apparatus and method for sensing gaps between labels adhered to a backing material in longitudinally spaced-apart positions as the backing material travels along the print path of a thermal printer. An array of light-emitting diodes oriented transverse to the print path illuminates the backing material. A fiber optic detects the light transmitted through the backing material and passes the light to a photodiode. The photodiode produces an analog electrical signal indicative of the amount of light transmitted, which varies depending on whether the light has passed through only the backing material or through both the backing material and the print media it carries. The analog signal is converted to a digital signal which is processed by a microprocessor to monitor and control the advancement of the print media and backing material through the printer.

Description:
TECHNICAL FIELD 
     The present invention relates to thermal printers and more particularly to a method and apparatus for measuring the gap between labels as they are being printed. 
     BACKGROUND OF THE INVENTION 
     It is known in the prior art to use printers with thermal printheads to produce contrasting images on a print medium such as a label stock. In one form, such printheads directly contact a thermally sensitive print medium. In others, a ribbon carrying a thermally transferrable dyed wax is placed between the printhead and a thermally insensitive print medium. 
     The wide applicability of such printers allows them to be used with different types of print medium, many of which use a printable material carried through the printer on a removable strip of backing material. The print medium may include separate pieces of printable material, such as self-adhesive labels, with gaps between the adjacent edges of the labels. The print medium can have many different characteristics, for example, having several different possible thicknesses. 
     It is important for the printer to coordinate the operation of the printhead and movement of the print medium, and especially the leading edges of the labels carried by the strip of backing material, so that the images can be placed in the desired position on the labels. Therefore it is desirable to have a printer that can sense the gaps between labels, or in other words, the leading or trailing edges of the labels, and control its operation based on the passage of the labels through the printer. 
     SUMMARY OF THE INVENTION 
     In one aspect, the invention is an apparatus for sensing the passage of print media carried by a continuous length of backing material in longitudinally spaced-apart positions along the length of the backing material as the backing material passes along a print path. 
     The apparatus comprises a light source and a light sensor. The light source is positioned along the print path producing a light on one side of the backing material which illuminates the backing material as it travels by the light source, the light source producing light of sufficient intensity to pass through the backing material. The light sensor is positioned along the print path to a side of the backing material opposite the light source at a position to receive light from the light source passing through the backing material, the light sensor detecting transmissivity based on the received light and generating an indicator signal indicative of whether the received light has passed through only the backing material or has passed through the backing material and the print media carried by the backing material. 
     In another aspect, the invention is a method for page sensing the passage of print media carried by a continuous length of backing material in longitudinally spaced-apart positions along the length of the backing material as the backing material travels along a print path. 
     The method comprises the steps of: (a) producing a light on one side of the backing material which illuminates the backing material as it travels along the print path, the light having a sufficient intensity to pass through the backing material; (b) receiving light from the light source at an opposite side of the backing material after it has passed through the backing material and any print media carried thereby; (c) detecting variations in the received light; and (d) generating an indicator signal based on detected variations in the received light indicative of whether the received light has passed through only the backing material or has passed through both the backing material and the print media carried by the backing material. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of a thermal printer using the present invention for printing on a print medium passing along a print path, the print path being closed. 
     FIG. 2 is a drawing of three labels attached to a backing material used with the thermal printer of FIG. 1. 
     FIG. 3 is a perspective view of the thermal printer of FIG. 1, with the print path being open. 
     FIG. 4 is a perspective view of a tracking section of the thermal printer of FIG. 1. 
     FIG. 5 is a perspective view of a print medium advancement mechanism used with the thermal printer of FIG. 1. 
     FIG. 6 is a perspective view of a guide mechanism used with the thermal printer of FIG. 1. 
     FIGS. 7A-7C comprise a block diagram of the electrical circuitry used with the thermal printer of FIG. 1. 
     FIG. 8 is a schematic diagram of a portion of a sensor used to control the thermal printer of FIG. 1. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     FIG. 1 is a perspective view of a thermal printer 20 for printing on a print medium passing along a print path. In FIG. 1 the print path is closed. The thermal printer 20 includes a first housing 22 and a second housing 24. The first housing 22 encloses electrical components mounted on printed circuit boards. The first housing 22 also includes a control panel 26 which allows the thermal printer 20 to be controlled and adjusted by a user. 
     The control panel 26 includes a liquid crystal display (LCD) 28, a plurality of buttons 30, and a plurality of light-emitting diodes (LEDs) 32. The LCD 28 provides an alphanumeric display of various commands useful for the user to control and adjust the thermal printer 20. The buttons 30 implement the user&#39;s choices of controls and adjustments, and the LEDs 32 provide displays of the status of the thermal printer 20. For example, one of the buttons 30 can be used to toggle the thermal printer 20 on- and off-line, with one of the LEDs 32 lighting to indicate when the printer is on-line. Another one of the buttons 30 can be used to select an array of menus including choices of print speeds and media types, among other choices. Another one of the buttons 30 can be used to reload or advance the print medium through the thermal printer 20. Yet another button 30 can be used to open the thermal printer 20 in order to change the print medium. 
     The second housing 24 includes a printer module 34 and a motor drive module 36 which are normally latched together. The printer module 34 and the motor drive module 36 are separated by a print medium path 38 along which the print medium passes. By activating another one of the buttons 30, the printer module 34 can be caused to unlatch from the motor drive module 36 so that it can be rotated backwards, in a clockwise direction, to the position seen in FIG. 3. This action opens the print medium path 38 and allows the adjustment and replacement of the print medium which is introduced into the print medium path 38 from a print medium roll 40 (see FIG. 1). 
     The print medium supplied on the print medium roll 40 is available in a variety of thicknesses, thermal sensitivities, and materials, depending upon the use to be made of the print medium. The print medium supplied from the print medium roll 40 passes through the print medium path 38 and exits through an opening 42 at the front of the second housing 24. If the print medium is a thermal transfer medium, a thermal transfer ribbon is placed in a separate drive mechanism (not shown) contained within the printer module 34. This separate drive mechanism provides supply and take-up rolls for the thermal transfer ribbon. The rolls for the thermal transfer ribbon are controllable independently of the movement of the print medium. This allows saving the ribbon when the print medium contains areas where no printing is required. The motor drive module 36 also contains a cooling fan (not shown) which exhausts air through a side grill 44. 
     A conventional print medium 45 shown in FIG. 2 comprises a long strip of backing material 46 with self-adhesive labels 48 adhered at spaced-apart positions along the length of the backing material, and the print medium is rolled to form the print medium roll 40. FIG. 2 shows three labels 48 adhered to a short segment of the backing material 46. The backing material 46 has a pair of parallel straight edges 50 extending in the direction the backing material travels along the print medium path 38. The labels 48 are spaced away from each of the edges 50 by a predetermined distance d. The labels 48 are separated from one another in the direction of travel of the backing material 46 by gaps 52, which extend perpendicularly to the edges 50. The invention is adapted to sense the presence of the gaps 52, or more precisely, the leading edge of a label, by the change in transmissivity of light through the backing material 46 which is caused by the presence or absence of a label 48. 
     The print medium 45 from the print medium roll 40 passes through the print medium path 38 with the side of the backing material to which the labels 48 of the print medium are attached facing up. As best shown in FIG. 5, the print medium 45 is advanced through the print medium path 38 by an advancement mechanism (to be described subsequently) and forced to pass between a platen roller 53 positioned within the motor drive module 36 at the opening 42 of the print medium path 38 and a thermal printhead 80 (to be described in FIG. 5), which is positioned within the printer module 34. The print medium 45, including the labels 48 which have been printed on, exit through the front opening 42 (see FIG. 1). 
     When the printer module 34 is latched to the motor drive module 36, the side of the print medium to which the labels 48 are adhered, is forced against the thermal printhead 80 by the platen roller 53. In order to accommodate a wide variety of print media, the pressure between the platen roller 53 and the printhead 80 is variably adjustable. 
     FIG. 3 is a perspective view of the thermal printer 20 of FIG. 1, with the print medium path 38 being open. FIG. 4 is a perspective view of the tracking section of the thermal printer 20. The motor drive module 36 includes a stepper motor 51 having a shaft 52 with a drive gear 54 attached near its end. The stepper motor 51 is controlled by electrical circuitry contained in the first housing 22. The electrical circuitry will be described subsequently. 
     The drive gear 54 engages a large gear 56 which drives a pulley 58. The pulley 58 engages a belt 60 which also passes over two equally-sized pulleys 62 and 64. The pulley 62 is attached to the end of a platen shaft 66 which drives the platen roller 53. The pulley 64 is attached to the end of a slew roller shaft 68 which supports a slew roller 70. A pinch roller 72, which is held by member 73, can be caused to rotate about a pivot shaft 74 toward the slew roller 70 with the print medium therebetween. When this happens, any print medium 45 passing through the print medium path 38 will be driven toward the front opening 42 by the driven slew roller 70. The speed at which the print medium is advanced toward the front opening 42 is governed by the rotational speed of the slew roller shaft 68. The platen shaft 66, which is driven at the same speed as the slew roller shaft 68, causes the print medium to pass between the platen roller 46 and the thermal printhead 80 (shown in FIG. 5) at the same speed. 
     When the thermal printer 20 is printing, the platen roller 53 moves the print medium 45. Otherwise, as will be seen, the platen roller 53 is not frictionally engaged with the print medium and the slew roller 70 working in conjunction with the pinch roller 72 advance the print medium through the thermal printer 20. 
     The motor drive module 36 also includes a guide mechanism 78 for guiding the backing material 46 through the print medium path 38. It includes edge guides 79 which guide the edges 50 of the backing material 46. 
     FIG. 5 is a perspective view of a preferred embodiment of an advancement mechanism 81 used with the thermal printer 20 of FIG. 1. The advancement mechanism 81 is placed below the guide mechanism 78 shown in FIG. 3 and 4. In the advancement mechanism 81 the printhead 80 pivots about a shaft 82 rotatably supported by a frame portion 83 of the printer module 34. The shaft 82 has one end affixed to an arm 84. Accordingly, a clockwise movement of the arm 84 (as viewed in FIG. 5) rotates the shaft 82 clockwise and causes the printhead 80 to move toward the platen roller 53. 
     The printer module 34 is connected to the motor drive module 36 when the thermal printer 20 is in use by a latch 120 which pivots about a latch shaft 122 that is rotatably supported by a frame portion 37 of the motor drive module 36. The latch 120, which is driven by a mechanism (not shown) in the motor drive module 36, engages a pin 124 which projects from the printer module 34. When latched, the printhead 80 is moved so that it is engaged against the print medium 45 passing between the platen roller 53 and the printhead 80. 
     FIG. 6 is a perspective view of a preferred embodiment of a guide mechanism for use with the invention. The mechanism includes a frame 130 having two arms 132 which are arranged parallel to one another to guide the backing material 46 received from the roll 40 through the print medium path 38 of the thermal printer 20. A first pair of the edge guides 79 is attached to the frame 130 and a second pair of the edge guides 79 is attached to the ends of the arms 132. The edge guides 79 engage the edges 50 of the 1 backing material 46 and keep the backing material properly located in the print medium path 38. 
     The thermal printer 20 uses a &#34;center tracking&#34; scheme which keeps the print medium 45 centered in the print medium path 38 regardless of the width of the print medium, which can range between 2.2 and 5.2 inches. The arms 132 are adjusted automatically to fit the width of the backing material 46 specified through the control panel 26 of the thermal printer 20. The frame 130 is located in the motor drive module 36 above. It has an aperture 134 through which the pinch roller 72 can reach the backing material. 
     An array of light-emitting diodes (LEDs) 136 is attached to one side of the frame 130, and extends perpendicularly to one of the arms 132 to cast a substantially uniform beam of light upward from the frame 130 toward the print medium path 38. Preferably the LEDs 136 emit infrared (IR) light. If the print medium 45 is loaded in the print medium path 38, the light cast by the array of LEDs 136 will strike the downward facing side of the backing material 46. 
     Opposing the array of LEDs 136 is a fiber optic holder 138, which holds an end portion of a flexible fiber optic 140 oriented perpendicularly to the array of LEDs 136 and a light receiving end of the fiber optic 140 facing toward the array to receive light it generates. The fiber optic holder 138 moves with the arm 132 to which it is attached. As noted above, the arm 132 moves laterally inward and outward to adjust to the width of the backing material 46 being used. The fiber optic 140 is held by the holder 138 so as to always be positioned inward of the adjacent edge 50 of the backing material 46 being guided through the print medium path 38. Therefore, depending upon the width of the backing material 46, the light receiving end of the fiber optic 140 will always be opposite one of the LEDs in the array of LEDs 136 with the backing material 46 therebetween. 
     The light collected by the end of the fiber optic 140 is directed to its other end 141 which is located opposite a conventional photodiode 225 which comprises part of a sensor 226, shown in FIGS. 7B and 8. The photodiode is terminated in a selectable load resistance, as will be described subsequently The sensor 226 produces an electrical signal whose level depends upon the amount of light collected by the fiber optic 140. This amount of light depends, in turn, upon whether the backing material 46 passing between the LEDs 136 and the fiber optic 140 has a label 48 attached thereto. This signal is sent to an analog-to-digital converter in the sensor 226. The information in the resulting digital signal is processed by a conventionally programmed print engine microprocessor to measure the actual lengths of the labels 48, the lengths of the gaps between the labels 48, or other features relating to the spacing of the labels 48 along the print medium 45, or even to sense the absence of the print medium 45 in the print medium path 38. 
     The components described above operate to detect changes in transmissivity between the print medium 45 above (a gap) and the print medium 45 with a label 48 adhered thereto. However, it will be understood by those skilled in the art that, while most labels 48 are somewhat transmissive, some could be opaque. In this case, the above-described components will still serve their functions well. It will also be understood by those skilled in the art that the same operation might be accomplished in some applications by placing the light source and the light detector in the same side of the backing as the print labels and detecting the changes in reflectivity as the labels pass by. 
     It will also be understood by those skilled in the art that to accommodate for both the variation in the sensitivity of the components chosen to implement the functions of the present invention and the wide range of transmissivity (or opacity) of the print media, the sensor 226 requires a gain setting that can be varied. That is accomplished by choosing an appropriate load resistance for the photodiode 225. As shown in FIG. 8, the load resistance is comprised of the resistors 227A, 227B, 227C, and 227D. These resistors 227 can be grounded through activation of their associated open collector devices 229A, 229B, 229C, and 229D. If the values of resistance of the resistors 227 are chosen correctly, the load resistance that could be applied to the photodiode 225 could have 2 4  different values. This can be accomplished by causing each of the resistors 227 to have a resistance that differs from the resistance of the others by a factor that is an integral power of two. The open collector devices 229 (which can be field effect transistors, open collector logic gates, etc.) are selectively activated, under software control, by the prior engine microprocessor 208. 
     With the above-described sensor 226, the thermal printer 20 can be calibrated to account for the variations described above. This is accomplished by passing a particular print medium through the printer 20 in a special calibrate mode that can be chosen by a user. In this calibrate mode, each available gain of the sensor 226 will be tried and one selected. The gain that is selected is the one that results in the largest difference between readings of the A/D converter 231 for the backing only and the backing and label together. 
     FIGS. 7A-7C comprise a block diagram of the electrical circuitry used with the guide mechanism of FIG. 6. The electrical circuitry includes a print engine microcomputer 202 and an image microcomputer 204. The print engine microcomputer 202 is primarily responsible for controlling the movement of the print medium 45 and the thermal transfer ribbon (if any) through the print medium path 38 and supplying print timing commands to the printhead 80. The image microcomputer 204 produces the images which are to be printed on the print medium. The print engine microcomputer 202 includes a print engine microprocessor 208, a read-only memory (ROM) 210, an input interface 212, and an output interface 214. The ROM 210 communicates with the print engine microprocessor 208 over bidirectional lines. The input interface 212 transmits input signals to the print engine microprocessor 208 and the print engine microprocessor 208 transmits output signals to the output interface 214. 
     The image microcomputer 204 includes an image microprocessor 216. The print engine microprocessor 208 and the image microprocessor 216 both communicate over bidirectional lines with a shared random access memory (RAM) 206. In addition, the print engine microprocessor 208 communicates interrupt signals to the image microprocessor 216 and the image microprocessor 216 communicates interrupt signals to the print engine microprocessor 208. 
     Through the output interface 214, the print engine microprocessor 208 sends control signals to a ribbon take-up drive 218, a ribbon supply drive 220, a stepper motor drive 222, and a head motor drive 224. The stepper motor drive 222 produces appropriate drive signals and transmits them to the stepper motor 51. Movements of the print medium 45 caused by the stepper motor 50 are sensed by the sensor 226 which produces signals that are transmitted to the input interface 212. The head motor drive 224 also produces appropriate signals and transmits them to the stepper motors 92, 150. Movements of the printhead 80 caused by the stepper motor 92, 150 are sensed by two sensors, the optical caliper detector 114 and a print module position sensor 228. The optical caliper detector 114 transmits signals to the input interface 212, indicating whether the printhead 80 is in the print mode or the idle mode. The print module position sensor 228 transmits signals to the input interface 212, indicating whether the printer module 34 is disengaged from the motor drive module 36. 
     As indicated above, detailed illustrative embodiments are disclosed herein. However, other embodiments, which may be detailed rather differently from the disclosed embodiments, are possible. Consequently, the specific structural and functional details disclosed herein are merely representative: yet in that regard, they are deemed to afford the best embodiments for the purposes of disclosure and to provide a basis for the claims herein, which define the scope of the present invention.