Abstract:
A receiving well for use with a thermal dye sublimation printing apparatus is disclosed. The receiving well is used to receive cut sheets printed using the thermal dye sublimation printing. The receiving well includes two angled surfaces, referred to herein as ramps. The ramps are spaced apart from one another, and a waste area is positioned between the two ramps. The waste area captures the scrap or waste paper that can result from cutting the receiver media after printing. In some embodiments, both ramps slope down to the bottom surface of the receiving well. In other embodiments, one of the ramps is raised off the bottom surface of the receiving well at its lowest point. The waste area may also be offset such that it is closer to one side of the receiving well than the other.

Description:
CROSS-REFERENCE TO RELATED CASES 
     This application claims the benefit of U.S. Provisional Application Ser. No. 61/867,336, entitled “OFFSET PRINT STACKING TRAY WITH WASTE AREA,” filed on Aug. 19, 2013. The aforementioned provisional application is hereby incorporated by reference in their entirety. 
    
    
     FIELD OF THE INVENTION 
     This invention pertains to an offset print stacking tray with anti stubbing feature and waste area. 
     BACKGROUND OF THE INVENTION 
     In thermal dye sublimation printing, it is generally well known to render images by heating and pressing one or more donor materials such as a colorant (e.g., a dye) or other coating against a receiver medium having a colorant receiving layer. The heat is generally supplied by a thermal print head having an array of heating elements. The donor materials are typically provided in sized donor patches on a movable web known as a donor ribbon. The donor patches are organized on the ribbon into donor sets; each set containing all of the donor patches that are to be used to record an image on the receiver web. For full color images, multiple color dye patches can be used, such as yellow, magenta, and cyan donor dye patches. Arrangements of other color patches can be used in like fashion within a donor set. Additionally, each donor set can include an overcoat or sealant layer. 
     Thermal printers offer a wide range of advantages in photographic printing including the provision of truly continuous tone scale variation and the ability to deposit, as a part of the printing process a protective overcoat layer to protect the images formed thereby from mechanical and environmental damage. Accordingly, many photographic kiosks and home photo printers currently use thermal printing technology. 
     Some thermal printing systems are adapted to print on individual sheets of receiver media. Thermal printing systems that are used for large volume applications (e.g., photographic kiosks) commonly utilize roll-fed receiver media. The roll size media may have various fixed dimensions. For example, a common roll fed media size is 8.5 inches wide. This type of media is capable of printing 8.5×11 inch images, or any length image dependent on donor patch length, but are restricted to 8.5 inches wide. However, with the addition of a dual center slitter, two 4×6 inch images can be printed side-by-side with a 0.5 inch center waste strip.  FIG. 5  shows a receiver tray commonly known in the art and used in current printing systems. This receiver tray receives the entire sheet of printed media, such as 8.5×11 inch, with no cutting into smaller prints, and stacking of the separate prints from multiple sheets of media. There remains a need in the art for a receiver tray with angled surfaces and a waste area, wherein individually cut smaller printed pieces of receiver media are received on the two angled surfaces of the tray and the waste strip of the receiver media is received in the waste area of the tray. There is also a need to automatically collate the images produced into an intended image order so that, instead of two stacks of images, the result of printing is one stack of ordered images. 
     SUMMARY OF THE INVENTION 
     The present invention is directed to a receiver tray for a thermal printer. The receiver tray has angled surfaces, a waste area, and is adapted to hold cut sheet media. 
     In one embodiment, the invention includes a receiver supply tray adapted to receive cut receiver media. The receiver supply tray includes a cut sheet receiving well having at least two side walls. The receiver supply tray also includes a first ramp disposed between the two side walls. The first ramp can be adjacent to one of the side walls. The receiver supply tray further includes a waste area between the first ramp and the non-adjacent side wall. The waste area can be adapted to receive the waste cut receiver media. The first ramp can be adapted to receive the printed cut receiver media. The receiver supply tray can also include a second ramp, and the second ramp can be positioned adjacent to a side wall opposite to the first ramp. 
     Another embodiment also includes a receiver supply tray adapted to receive cut sheet media. The receiver supply tray includes a cut sheet receiving well having at least a first and a second side wall. The receiver supply tray can also include a first ramp adjacent to a first sidewall adapted to receive a first printed cut receiver media. A second ramp can be included, and can be located adjacent to a second sidewall. The second ramp can be adapted to receive a second printed cut receiver media. The first and second ramps can define a waste area adapted to receive waste cut receiver media. The waste area can be located between the first and second ramps. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  shows a system diagram for an exemplary thermal printing system that can be used in practicing the present invention; 
         FIG. 2  is a diagram showing a bottom view of a thermal printhead used in  FIG. 1 ; 
         FIG. 3A  is a diagram illustrating a donor ribbon having four different donor patches that can be used with the system shown in  FIG. 1 ; 
         FIGS. 3B-3C  illustrate a printing operation using the system shown in  FIG. 1 ; 
         FIG. 4  is a diagram illustrating components of the thermal printing system shown in  FIG. 1 ; 
         FIG. 5  is a pictorial illustrating a receiver tray commonly known in the art; 
         FIG. 6  is a pictorial illustrating a receiver tray with angled surfaces for print guidance and center waste area according to an aspect of the present invention; 
         FIG. 6A  is a pictorial of the tray of  FIG. 6  with the hidden edges shown using dashed lines; 
         FIG. 7  is a pictorial illustrating a receiver tray with angled surfaces for print guidance and center waste area according to another aspect of the present invention; 
         FIG. 7A  is a pictorial of the tray of  FIG. 6  with the hidden edges shown using dashed lines; 
         FIG. 8  is a diagram illustrating a duplex thermal printing system using two thermal printheads; 
         FIG. 9  is a diagram illustrating an alternate duplex thermal printing system that includes a turning mechanism for repositioning the receiver supply roll; 
         FIG. 10  is a diagram illustrating an alternate duplex thermal printing system using a turn roller; 
     
    
    
     It is to be understood that the attached drawings are for purposes of illustrating the concepts of the invention and may not be to scale. 
     DETAILED DESCRIPTION OF THE INVENTION 
     The invention is inclusive of combinations of the aspects of the present invention described herein. References to “a particular aspect” and the like refer to features that are present in at least one aspect of the invention. Separate references to “an aspect” or “particular aspects” or the like do not necessarily refer to the same aspect or aspects; however, such aspects are not mutually exclusive, unless so indicated or as are readily apparent to one of skill in the art. The use of singular or plural in referring to the “method” or “methods” and the like is not limiting. It should be noted that, unless otherwise explicitly noted or required by context, the word “or” is used in this disclosure in a non-exclusive sense. 
       FIG. 1  shows a system diagram for an exemplary thermal printer  18  that can be used to practice the present invention. As shown in  FIG. 1 , thermal printer  18  has a printer controller  20  that causes a thermal print head  22  to record images onto receiver media  26  by applying heat and pressure to transfer material from a donor ribbon  30  to receiver media  26 . The receiver media  26  includes a dye receiving layer coated on a substrate. As used herein, the term “receiver media” is used synonymously with the terms “thermal imaging receiver” and “thermal media.” Similarly, the term “donor ribbon” is used synonymously with the terms “thermal donor” and “donor web.” 
     Printer controller  20  can include, but is not limited to: a programmable digital computer, a programmable microprocessor, a programmable logic controller, a series of electronic circuits, a series of electronic circuits reduced to the form of an integrated circuit, or a series of discrete components. According to an aspect of the invention shown in  FIG. 1 , printer controller  20  also controls receiver pick rollers  41 , a receiver drive roller  42 , receiver exit rollers  43 , a donor ribbon take-up roll  48 , and a donor ribbon supply roll  50 ; which are each motorized for rotation on command of the printer controller  20  to effect movement of receiver media  26  and donor ribbon  30 . 
       FIG. 2  shows a bottom view according to one aspect of a typical thermal print head  22  with an array of thermal resistors  49  fabricated in a ceramic substrate  45 . A heat sink  47 , typically in the form of an aluminum backing plate, is fixed to a side of the ceramic substrate  45 . Heat sink  47  rapidly dissipates heat generated by the thermal resistors  49  during printing. As shown in  FIG. 2 , the thermal resistors  49  are arranged in a linear array extending across the width of platen roller  46  (shown in phantom). Such a linear arrangement of thermal resistors  49  is commonly known as a heat line or print line. However, other non-linear arrangements of thermal resistors  49  can be used in various aspects of the present invention. Further, it will be appreciated that there are a wide variety of other arrangements of thermal resistors  49  and thermal print heads  22  that can be used in conjunction with the present invention. 
     The thermal resistors  49  are adapted to generate heat in proportion to an amount of electrical energy that passes through thermal resistors  49 . During printing, printer controller  20  transmits signals to a circuit board (not shown) to which thermal resistors  49  are connected, causing different amounts of electrical energy to be applied to thermal resistors  49  so as to selectively heat donor ribbon  30  in a manner that is intended to cause donor material to be applied to receiver media  26  in a desired manner. 
     As is shown in  FIG. 3A , donor ribbon  30  comprises a first donor patch set  32 . 1  having a yellow donor patch  34 . 1 , a magenta donor patch  36 . 1 , a cyan donor patch  38 . 1  and a clear donor patch  40 . 1 ; and a second donor patch set  32 . 2  having a yellow donor patch  34 . 2 , a magenta donor patch  36 . 2 , a cyan donor patch  38 . 2  and a clear donor patch  40 . 2 . Each donor patch set  32 . 1  and  32 . 2  has a patch set leading edge L and a patch set trailing edge T. In order to provide a full color image with a clear protective coating, the four patches of a donor patch set; are printed, in registration with each other, onto a common image receiving area  52  of receiver media  26  shown in  FIG. 3B . The printer controller  20  ( FIG. 1 ) provides variable electrical signals in accordance with input image data to the thermal resistors  49  ( FIG. 2 ) in the thermal print head  22  in order to print an image onto the receiver media  26 . Each color is successively printed as the receiver media  26  and the donor ribbon move from right to left as seen by the viewer in  FIG. 3B . 
     During printing, the printer controller  20  raises thermal print head  22  and actuates donor ribbon supply roll  50  ( FIG. 1 ) and donor ribbon take-up roll  48  ( FIG. 1 ) to advance a leading edge L of the first donor patch set  32 . 1  to the thermal print head  22 . In the embodiment illustrated in  FIGS. 3A-3C , leading edge L for first donor patch set  32 . 1  is the leading edge of yellow donor patch  34 . 1 . As will be discussed in greater detail below, the position of this leading edge L can be determined by using a position sensor to detect an appropriate marking indicia on donor ribbon  30  that has a known position relative to the leading edge of yellow donor patch  34 . 1  or by directly detecting the leading edge of yellow donor patch  34 . 1 . 
     Printer controller  20  also actuates receiver pick rollers  41  ( FIG. 1 ) to pick cut sheet receiver from receiver supply cassette  44  ( FIG. 1 ) into drive roller  42  ( FIG. 1 ). Printer controller  20  also actuates drive roller  42  ( FIG. 1 ), so that image receiving area  52  of receiver media  26  is positioned with respect to the thermal print head  22 . In the embodiment illustrated, image receiving area  52  is defined by a receiving area leading edge LER and a receiving area trailing edge TER on receiver media  26 . Donor ribbon  30  and receiver media  26  are positioned so that donor patch leading edge LED of yellow donor patch  34 . 1  is registered at thermal print head  22  with receiving area leading edge LER of image receiving area  52 . Printer controller  20  then causes a motor or other conventional structure (not shown) to lower thermal print head  22  so that a lower surface of donor ribbon  30  engages receiver media  26  which is supported by platen roller  46 . This creates a pressure holding donor ribbon  30  against receiver media  26 . 
     Printer controller  20  then actuates receiver drive roller  42  ( FIG. 1 ), donor ribbon take-up roll  48  ( FIG. 1 ), and donor ribbon supply roll  50  ( FIG. 1 ) to move receiver media  26  and donor ribbon  30  together past the thermal print head  22 . Concurrently, printer controller  20  selectively operates thermal resistors  49  ( FIG. 2 ) in thermal print head  22  to transfer donor material from yellow donor patch  34 . 1  to receiver media  26 . 
     As donor ribbon  30  and receiver media  26  leave the thermal print head  22 , a peel member  54  ( FIG. 1 ) separates donor ribbon  30  from receiver media  26 . Donor ribbon  30  continues over idler roller  56  ( FIG. 1 ) toward the donor ribbon take-up roll  48 . As shown in  FIG. 3C , printing continues until the receiving area trailing edge TER of image receiving area  52  of receiver media  26  reaches the printing zone between the thermal print head  22  and the platen roller  46 . The printer controller  20  then adjusts the position of donor ribbon  30  and receiver media  26  using a predefined pattern of movements so that a leading edge of each of the next donor patches (i.e., magenta donor patch  36 . 1 ) in the first donor patch set  32 . 1  are brought into alignment with receiving area leading edge LER of image receiving area  52  and the printing process is repeated to transfer further material to the image receiving area  52 . This process is repeated for each donor patch thereby forming the complete image. 
     Returning to a discussion of  FIG. 1 , the printer controller  20  operates the thermal printer  18  based upon input signals from a user input system  62 , an output system  64 , a memory  68 , a communication system  74 , and sensor system  80 . The user input system  62  can comprise any form of transducer or other device capable of receiving an input from a user and converting this input into a form that can be used by printer controller  20 . For example, user input system  62  can comprise a touch screen input, a touch pad input, a 4-way switch, a 6-way switch, an 8-way switch, a stylus system, a trackball system, a joystick system, a voice recognition system, a gesture recognition system or other such user input systems. An output system  64 , such as a display or a speaker, is optionally provided and can be used by printer controller  20  to provide human perceptible signals (e.g., visual or audio signals) for feedback, informational or other purposes. 
     Data including, but not limited to, control programs, digital images and metadata can also be stored in memory  68 . Memory  68  can take many forms and can include without limitation conventional memory devices including solid state, magnetic, optical or other data storage devices. In  FIG. 1 , memory  68  is shown having a removable memory interface  71  for communicating with removable memory (not shown) such as a magnetic, optical or magnetic disks. The memory  68  is also shown having a hard drive  72  that is fixed with thermal printer  18  and a remote memory  76  that is external to printer controller  20  such as a personal computer, computer network or other imaging system. 
     As shown in  FIG. 1 , printer controller  20  interfaces with a communication system  74  for communicating with external devices such as remote memory  76 . The communication system  74  can include for example, a wired or wireless network interface that can be used to receive digital image data and other information and instructions from a host computer or network (not shown). 
     A sensor system  80  includes circuits and systems that are adapted to detect conditions within thermal printer  18  and, optionally, in the environment surrounding thermal printer  18 , and to convert this information into a form that can be used by the printer controller  20  in governing printing operations. Sensor system  80  can take a wide variety of forms depending on the type of media therein and the operating environment in which thermal printer  18  is to be used. 
     As shown in  FIG. 1 , sensor system  80  includes an optional donor position sensor  82  that is adapted to detect the position of donor ribbon  30 , and a receiver position sensor  84  that is adapted to detect a position of the receiver media  26 . The printer controller  20  cooperates with donor position sensor  82  to monitor the donor ribbon  30  during movement thereof so that the printer controller  20  can detect one or more conditions on donor ribbon  30  that indicate a leading edge of a donor patch set. In this regard, the donor ribbon  30  can be provided with markings or other optically, magnetically or electronically sensible indicia between each donor patch set (e.g., donor patch set  32 . 1 ) or between donor patches (e.g., donor patches  34 . 1 ,  36 . 1 ,  38 . 1 , and  40 . 1 ). Where such markings or indicia are provided, donor position sensor  82  is provided to sense these markings or indicia, and to provide signals to controller  20 . The printer controller  20  can use these markings and indicia to determine when the donor ribbon  30  is positioned with the leading edge of the donor patch set at thermal print head  22 . In a similar way, printer controller  20  can use signals from receiver position sensor  84  to monitor the position of the receiver media  26  to align receiver media  26  during printing. Receiver position sensor  84  can be adapted to sense markings or other optically, magnetically or electronically sensible indicia between each image receiving area of receiver media  26 . 
     During a full image printing operation, the printer controller  20  causes donor ribbon  30  to be advanced in a predetermined pattern of distances so as to cause a leading edge of each of the donor patches (e.g., donor patches  34 . 1 ,  36 . 1 ,  38 . 1 , and  40 . 1 ) to be properly positioned relative to the image receiving area  52  at the start each printing process. The printer controller  20  can optionally be adapted to achieve such positioning by precise control of the movement of donor ribbon  30  using a stepper type motor for motorizing donor ribbon take-up roll  48  or donor ribbon supply roll  50  or by using a movement sensor  86  that can detect movement of donor ribbon  30 . In one example, a follower wheel  88  is provided that engages donor ribbon  30  and moves therewith. Follower wheel  88  can have surface features that are optically, magnetically or electronically sensed by the movement sensor  86 . 
     According to one aspect of the present invention, the follower wheel  88  that has markings thereon indicative of an extent of movement of donor ribbon  30  and the movement sensor  86  includes a light sensor that can sense light reflected by the markings. According to other aspects of the present invention, perforations, cutouts or other routine and detectable indicia can be incorporated onto donor ribbon  30  in a manner that enables the movement sensor  86  to provide an indication of the extent of movement of the donor ribbon  30 . 
     Optionally, donor position sensor  82  can be adapted to sense the color of donor patches on donor ribbon  30  and can provide color signals to controller  20 . In this case, the printer controller  20  can be programmed or otherwise adapted to detect a color that is known to be found in the first donor patch in a donor patch set (e.g., yellow donor patch  34 . 1  in donor patch set  32 . 1 ). When the color is detected, the printer controller  20  can determine that the donor ribbon  30  is positioned proximate to the start of the donor patch set. 
       FIG. 4  shows additional details for components of a thermal printing system  400  according to an aspect of the present invention. Donor ribbon supply roll  50  supplies donor ribbon  30 , which is received by take-up roll  48 . A receiver supply media cassette  44  supplies cut sheet receiver media  26 . Receiver media  26  and donor ribbon  30  are merged together between platen roller  46  thermal print head  22 , which includes a heat sink  90  and a peel member  92 . Subsequent to the thermal print head  22  transferring donor material from the donor ribbon  30  to the receiver media  26 , the peel member  92  separates the donor ribbon  30  from the receiver media  26 . The donor ribbon  30  continues to travel on to the donor ribbon take-up roll  48 , while the receiver media  26  travels between a pinch roller  94  and a capstan roller  96  that form a nip. 
     There are many applications where it is desirable to print images on both sides of the receiver media  26 . For example, photo calendars and photo book pages generally have photographs or other content (e.g., text and graphics) printed on both sides of each page. To print duplex thermal prints, the receiver media  26  should have dye receiving layers coated on both sides of a substrate. Various arrangements can then be used to transfer dye onto both sides of the receiver media  26 . 
       FIG. 8  shows one arrangement that can be used for a duplex thermal printing system  410 . In this configuration, the main printing components shown in the arrangement of  FIG. 4  are duplicated, with one being arranged to print on each side of the receiver media  26 . A first thermal print head  22 A transfers dye from a first donor ribbon  30 A onto a first side of the receiver media  26 , and a second thermal print head  22 B transfers dye from a second donor ribbon  30 B onto a second side of the receiver media  26 . This configuration has the advantage that two-sided images can be printed without complex paper handling mechanism. The main disadvantage of this approach is that it adds significant cost to the printer since it doubles the number of thermal print heads  22 A and  22 B and other associated components. It also requires a longer media path, and therefore increases the printer size accordingly. Another disadvantage is that two rolls of donor ribbon  30 A and  30 B must be used, which means that the printer operator will need to stock larger numbers of rolls, and if the donor ribbons  30 A and  30 B are used at different rates they may need to service the printer more frequently to reload donor ribbon when one of the rolls is used up. 
       FIG. 9  shows another arrangement that can be used for a duplex thermal printing system  420 . In this configuration, which is similar to that used in the KODAK D4000 Duplex Photo Printer, the receiver supply roll  51  is provided with a turning mechanism (not shown) that enables it to be pivoted from a first position  422  to a second position  424 . After the first side of the image has been printed using the thermal print head, the receiver media  26  is wound back onto the receiver supply roll  51 . The receiver supply roll  51  is then pivoted into the second position  424  and the receiver media  26  is rethreaded between the thermal print head  22  and the platen roller  46 . The opposite side of the receiver media will now be facing the thermal print head  22  so that the second side of the image can be printed. The main disadvantage of this approach is that the turning mechanism for the receiver supply roll  51  adds significant cost to the printer. Since the receiver supply roll  51  is typically quite large relative to the size of the printer, the printer size must also be increased to provide space to position the receiver supply roll  51  into the second position  424 . 
       FIG. 10  shows a duplex thermal printing system  430  that includes a turning mechanism for turning over the receiver media  26 . In this configuration a cutter  432  is provided that can be used to cut the receiver media  26 . The cutter  432  can be adjusted to cut the receiver media into various sizes. Some of the cut receiver media may correspond to printed images and some of the cut receiver media may be waste. 
     As shown in  FIGS. 6 and 6A , the receiver tray  44  includes a cut sheet receiving well comprising at least two side walls, two angled surfaces, and a waste area disposed between the first and second angled surfaces. The cut receiver media with printed images is received onto the angled surfaces from the thermal printer. As noted above, an 8.5 inch-wide roll fed media can be used to print two 4×6 inch images in portrait mode with a 0.5 inch center waste strip. This waste strip is received into the waste area and is automatically separated from the printed receiver media. Separation of the waste strip from the printed media is enhanced by the angle of the angled surfaces, also referred to herein as ramps. As shows in  FIGS. 6, 6A, 7 , and  7 A, the ramps can be slanted towards their respective adjacent sidewalls. This slant causes gravity to pull the two printed receiver media away from the waste strip, thus aiding in separating the waste strip. 
       FIGS. 7 and 7A  show another aspect of the present invention where the bottom edge of one of the angled surfaces is higher than the bottom edge of the other angled surface. This difference is height in the edges allows for the media received on the two angled surfaces to be interleaved in a manner that retains the order of the print sequence. Specifically, because the angled surface with the higher bottom edge has a lower slope than the other angled surface, the printed receiver media deposited onto the angled surface with the higher bottom edge reaches the base of the receiver tray shortly after the printed receiver media deposited onto the angled surface with the lower bottom edge. Although the receiver tray depicted in  FIGS. 6, 6A, 7, and 7A  has a rectangular shape, the receiver tray can have a trapezoidal or triangular shape in order to further facilitate interleaving or collating of the printed receiver media. When the receiver tray is rectangular, the result of using the receiver tray is two separate stacks of printed receiver media. However, when the receiver tray has a trapezoidal or triangular shape in which the width of the receiver tray at the high end of the ramps is greater than the width of the receiver tray at the low end of the ramps, the result of using the receiver tray is a single interleaved, or collated, stack of printed receiver media. When a trapezoidal or triangular receiver tray is used and the bottom edge of one of the angled surfaces is higher than the bottom edge of the other angled surface, the printed receiver media can be printed such that the resulting collated stack is in a known, predetermined order. 
     Further, although the waste area of  FIGS. 6 and 7  is shown in the center, it is obvious to one skilled in the art that arrangements of the angled surfaces can permit the waste area to be offset towards one of the side walls to allow prints of differing sizes to be received on each of the two angled surfaces. In other embodiments, the waste area can be positioned directly adjacent to one of the sidewalls, or two waste areas can be provided, one adjacent to each sidewall. These waste areas can be provided in addition to a central waste area, or can be provided without the central waste area. Positioning the waste areas in this manner allows for trapping waste paper when the edges of the receiver media are trimmed. In another aspect of the present invention, the width of the angled ramps can be adjusted to move the waste area to a desired location in the receiver tray based on the sizes of the cut receiver media with printed images. In yet another aspect of the present invention, there may only be one angled ramp to receive cut printed receiver media with the waste area located adjacent to one of the side walls. 
     The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.