Patent Publication Number: US-11034172-B2

Title: Feeding a print medium and printer

Description:
BACKGROUND 
     Scanning printers are based on a system with two perpendicular axes: the media advance axis and the print head scan axis. The media advance axis defines the movement and position of a print medium below a print head when the print head prints a swath of printing fluid. The print head scan axis defines the movement of a print head carriage carrying the print head. A firing pulse is generated in response to the position of the print head in the print head scan axis. The firing pulse is a signal used by the print head to fire a drop of printing fluid while the media is static below the carriage. 
     A Page Wide Array (PWA) printer has an axis architecture in which the print head carriage is replaced by an array of nozzles that extends in a width direction across a print zone and does not move. The print medium moves through the print zone, with the media advance axis perpendicular to the width direction of the array of pens. A firing pulse is generated in a respective nozzle in response to the media movement. 
     The media advance axis also is referred to as Y direction, and the print head scan axis or nozzle array width also is referred to as X direction. Media position errors in the X direction might cause print image quality issues. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  shows a perspective view of part of a printer according to an example; 
         FIG. 2A to 2C  show sectional views of part of a printer in different operating states, according to an example; 
         FIGS. 3A and 3B  show top views of a media advance system according to an example; 
         FIGS. 4A and 4B  show schematic top views of a media advance system according to another example; 
         FIGS. 5A and 5B  show schematic top views of a media advance system according to another example; 
         FIG. 6  shows a flow diagram of a process of feeding a print medium according to an example; and 
         FIG. 7  shows a simplified vacuum system mass flow transitory scheme according to an example. 
     
    
    
     DESCRIPTION OF EXAMPLES 
       FIGS. 1 and 2A to 2C  show a perspective view and cross-sections through a part of a printer according to an example. The printer of this example is a page wide array printer wherein the figures show a media advance system  10  arranged between a media input  12  and a media output  14 . A print medium, such as a single sheet or a continuous web of print media is fed to the media input side from an input tray, a drawer or roll of paper, for example. The media advance system  10  provides certain features to isolate the media movement between the feeder and the media advance system. The media advance system  10  generates a bubble or curvature in the print medium while being transported and while printing to avoid back tension, to enable printing without stopping media transport, and to allow cutting of the print media while printing. 
     The media advance system  10  comprises a first set of feed rollers/pinch wheel pairs  16  and a second set of pinch wheels  18 , and a number of movable baffles  20  between the first set and the second set. A print medium  100  (see  FIGS. 2B and 2C ) is fed to the first set of feed rollers/pinch wheel pairs  16 , and once the leading edge of the print medium  100  has passed the first set  16 , the baffles  20  are raised (see  FIG. 2B ), e.g. by rotating the baffles  20  around an axis  20 ′ to lift a front end  20 ″ of each baffle  20 . This causes the print medium to be lifted up and deform to generate a media bubble  102  or curvature (in the following, referred to as media bubble) while it continues to be fed to the second set of pinch wheels  18  and from there to a platen and set of vacuum belts  22  (see  FIG. 2C ). A positive difference between the feed roller speed of the first set  16  and the speed of the vacuum belts  22  allows generating and maintaining the media bubble  102  upstream of the vacuum belts  22 . The media bubble  102  allows the first set of feed rollers/pinch wheel pairs  16  to stop feeding the print medium  100  when a print is about to be completed, cut the print medium  100 , and start again the first set of feed rollers/pinch wheel pairs  16  to deliver the trailing edge of the print medium  100  without having to stop the printing operation. The second set of pinch wheels  18  ensures media flatness before the leading edge of the print medium reaches the vacuum belts  22 . 
     A media bubble sensor  28  is provided between the first set of feed rollers/pinch wheel pairs  16  and the second set of pinch wheels  18  wherein the bubble sensor  28  can be extended from a guiding plate  30  or retracted behind the plate  30 .  FIG. 1  shows the bubble sensor  28  in the extended position. When a media bubble  102  is desired to allow cutting of the print medium  100 , for example, the bubble sensor  28  can be extended to ensure a minimum media bubble size. 
     In this example, a print bar or print nozzle array  32  is schematically shown in  FIGS. 1 and 2A to 2C , extending above a print zone (described with reference to  FIGS. 3A and 3B ) across the media advance system  10  in an X direction, perpendicular to the media advance direction Y. In  FIG. 2A to 2C , the print bar  32  extends normal to the drawing plane. 
     In the example, the media advance system  10  comprises six parallel vacuum belts  22  which are driven by common idle/drive rollers  24  and  26 . The media advance system  10  further comprises a vacuum chamber  40  that is formed underneath a platen  42  and is in fluid communication with the surface of the platen  42  through a plurality of suction ports  44 . The vacuum chamber  40  can be partially evacuated by means of a vacuum generator, including a fan or pump  48  to reduce the pressure in the vacuum chamber  40  with respect to the atmospheric pressure in the surrounding environment. The vacuum generator may be provided within the vacuum chamber  40  or externally thereto, with a fluid connection to the vacuum chamber  40 . It generates a suction force or vacuum force at the surface of the platen  42  which may be characterized in terms of a pressure that is locally decreased with respect to a pressure in a surrounding environment, in particular, locally decreased with respect to an atmospheric pressure. The vacuum force is transferred to the print medium  100  transported on the surface of the vacuum belt  22  and is translated into a normal force and a traction force which causes the print medium to follow the movement of vacuum belts  22 . 
     The media advance system  10  further may include a position sensor (not shown) to detect a leading edge and/or a trailing edge of the print medium  100  when it is transported across the platen  42 . A plurality of position sensors can be provided, e.g. at an upstream end and at a downstream end of the platen  42 , and/or at an upstream end and at a downstream end of a print zone, in the media advance direction. 
     The media advance system  10  further may be coupled with a controller (not shown) for controlling movement and speed of the first set of feed rollers/pinch wheel pairs  16 , and of the idle/drive rollers  24 ,  26 , and further for controlling movement of the baffle  20 . The controller further can control the vacuum level generated in the vacuum chamber  40 . The controller can comprise one or a number of dedicated microcontrollers or other processing means. 
       FIGS. 3A and 3B  are top views of a platen/belt portion of the media advance system  10  of a PWA printing device. In this portion, the media advance system comprises the platen  42  and a plurality of vacuum belts  112   a  to  112   f , in this example six (6) belts, that transport a print medium  114 , such as a sheet of paper or continuous web of paper from the second set of pinch wheels  18  through a print zone  118  to a media output zone  120  along a media advance direction Y (indicated by an arrow in  FIGS. 3A and 3B ). The vacuum belts  112   a  to  112   f  transport the print medium  114  to the print zone  118 , where print heads print on the upper side of the print medium  114 . The print heads are located above the platen  42  and the print medium  114  in the print zone  118 , but are not shown in  FIGS. 3A and 3B  to streamline the presentation. The print heads may be provided in the form of a print bar, which includes an array of nozzles that extends in a width direction across a print zone and does not move. The print head alternatively may be provided in a carriage which scans across the print medium in a width direction of the print zone. Firing pulses are generated to eject droplets of printing fluid, either from the static print bar or from the scanning print heads, when the print medium is below the print heads in the print zone. Printing fluid may refer to a fluid that may be dispensed by an inkjet-type printer or other inkjet-type dispenser and may include inks, varnishes, and/or post/pre-treatment agents, for example. During printing, the print medium  114  is advanced continuously or incrementally to the media output zone  120  and output from the printing device. 
       FIG. 3A  shows a scenario where the leading edge of the print medium  114  just reaches the print zone  118 , and  FIG. 3B  shows a scenario with the trailing edge of the print medium  114  leaves the print zone  118 . The print medium may be longer than shown in the drawings and may extend beyond the media input zone  116  in  FIG. 3A  and the media output zone  120  in  FIG. 3B , respectively. 
     The upper surface of the platen  42  is provided with a plurality of suction ports  122  in the form of small holes distributed across the entire platen  42 . The suction ports  122  are in fluid communication with the vacuum chamber (not shown in  FIGS. 3A and 3B ) located underneath the platen  42 . A vacuum source such as a fan or pump (not shown in  FIGS. 3A and 3B ) is located in or in fluid communication with the vacuum chamber and establishes a vacuum in the vacuum chamber. A vacuum may be characterized in terms of a reduced pressure with respect to the pressure in the surrounding environment, such as with respect to an atmospheric pressure. Due to the fluid communication with the suction ports  122 , the vacuum in the vacuum chamber applies a suction force to the underside of the print medium  114  on the platen  42 . 
     The vacuum belts  112   a  to  112   f  on the surface of the platen  42  may likewise be provided with little holes or openings that allow air to pass through and hence facilitate the application of the suction force to the underside of the print medium  114 . 
     Due to the suction force, the print medium  114  is tightly held and can be positioned on the vacuum belts  112   a  to  112   f  while being advanced along the media advance direction Y. The suction force also avoids curling of the print medium  114 , which could lead to media jams or degrade the printing quality. 
     A number of vacuum belts  112   a  to  112   f  share common rollers, such as a drive roller  26  and an idle roller  24 . The vacuum holds down the print medium, provided flatness for accurate ink dot placement and providing a normal force to the print medium for generating traction to avoid slippage of media-to-belt when the print medium is transported by the vacuum belts  112   a - 112   f.    
     Different causes can generate a media registration error in the X direction, i.e. perpendicular to the print media advance direction Y. A media registration error in the X direction may increase with an increase of media length wherein the print medium may make a kind of rotational movement defining a curve. The X axis registration error may reach a maximum when there is equilibrium between a tension force applied to the print medium in the media advance direction and a traction force applied to the print medium for holding the print medium on the media advance system. This is explained with reference to  FIGS. 4A, 4B, 5A and 5B . 
       FIG. 4A  shows an example where a single sheet feeder  50  feeds a single sheet of print medium  55  to a media advance system  52 . An initial position of the print medium  55  is shown in solid lines and subsequent positions are shown in broken lines. If the sheet feeder  50  is misaligned relative to the media advance system  52 , e.g. tilted at an angle, this causes a skew of the print medium when it is transported through the print zone. This in turn causes a linear error in the X direction of the print media position. For example, if the feeder  50  is angled at 0.5° relative to the advance direction, the print medium  55  will have the same angle and will be transported through the print zone at the same angle. This results in a slope of 8.7 mm/m, which means that the lateral position (position in the X direction) of the print medium at a predetermined position in the Y direction will move by 8.7 mm after one meter (1 m) of media advance in the media advance or Y direction. 
       FIG. 4B  shows another example where a single sheet feeder  50  feeds a single sheet of print medium  55  to a media advance system  52 . In this case, it is assumed that the print medium is transported on two vacuum belts and the two neighboring vacuum belts of the media advance system  52  run at different speeds. The two sides of the print medium  55  are transported each on one of the two neighboring vacuum belts and will move at a different speed in the media advance direction Y. This causes the print medium  55  to rotate, causing a non-linear misalignment of the print medium  55  relative to the print heads. The initial position of the print medium  55 , when it enters the media advance system  52 , is shown in solid lines and subsequent positions are shown in broken lines. For short plots or short print media, this might be negligible. However, for longer plots, e.g. having a length of 1 m or above, where the Y dimension of the print medium is much bigger than the X dimension, the rotation may cause a noticeable position error of the print medium in the X direction. A small differential advance between the two sides of the print medium can cause a significant position error in the X direction. An example of a “long plot” is a plot on a print medium having a length of 80 cm or above, 1 m or above, 1.2 m or above, or having a length which is 2.5 times its width or more. 
     If using vacuum belts, a non-symmetric belt speed profile can be caused by a misalignment between drive rollers or the use of vacuum belts generating non-homogeneous friction forces distributed across the print medium, for example. Another cause for a position error can be the use of a grit roller for transporting the print medium having a conical shape in the roller. 
       FIGS. 5A and 5B  show a similar scenario as  FIG. 4B  for a “long plot”, as defined above, i.e. for a plot which is printed on a print medium having a length of e.g. 80 cm or above, or 1 m or above, or 1.2 m or above. In  FIG. 5A , a print medium  65  for a long plot is fed from a sheet feeder  60  to the media advance system  52 , with a buffer area  62  between the sheet feeder  60  and the media advance system  52 . The buffer area  62 , in an example, may be provided between the first set  16  and the second set  18  of feed rollers/pinch wheels, as shown in  FIGS. 1 and 2 . A media bubble may be generated in the buffer area  62  between the sheet feeder  60  and the media advance system  52 , as explained with reference to  FIGS. 1 and 2 . A portion  65  of the print medium, when the print medium traverses the sheet feeder  60 , is represented in solid lines; and a further portion  65 ′ of the print medium, when the print medium traverses the media advance system, is represented in broken lines. Both portions  65 ,  65 ′ are part of a continuous web of the print medium for producing a “long plot”. 
     In  FIG. 5B , it is assumed that the print medium has advanced further and the rotation angle of the print medium  65  has increased continuously with the advance of the medium  65  in the Y direction. The portion  65 ″ of the print medium has reached a stable X position where the force that makes the print medium rotate is equal to the tension force applied to the print medium between the media advance system and the upstream feed rollers/pinch wheels, i.e. there is an equilibrium between the tension force and the traction force applied to the print medium. In this scenario, the media bubble on one side of the print medium, opposite to the rotation center (in  FIG. 5B  at the right-hand side), has been consumed so that the print medium is fully tensioned and flat at the respective edge; and the media bubble on the other side of the print medium, facing the rotation center (in  FIG. 5B  at the left-hand side), has increased because the print medium is compressed at the respective edge. This can be expressed as no-media-bubble and bigger-media-bubble at the two edges of the print medium  65 . 
     In the scenario  FIG. 5B , the tension applied to the print medium has increased to a level where it is equal to the traction force applied to the print medium by the vacuum belts. In this stable position, the tension force may at least partially overcome the traction force so that the print medium slips in the X direction and compensates for at least some of the X position registration error. Accordingly, there is a dependency between the traction force generated by the vacuum belts and tension force used to overcome the traction force. The higher the vacuum level, the higher the tension force to make the medium slip in the X direction and, accordingly, the larger will be the stable angle of the print medium and hence the absolute registration error in the X position of the print medium within the print zone. 
     The X axis registration error can be reduced if the stable position is obtained at a lower tension force. On the other hand, the traction force should not be lowered arbitrarily. A certain minimum traction should be maintained when the leading edge and the trailing edge of the print medium enter and leave the print zone. A minimum vacuum level at the beginning and at the end of the plot also is useful to create a normal force to iron the leading and the trailing edges of the print media. 
     The vacuum level generated in the vacuum chamber and hence the normal force (suction force) applied to the print medium  65  can be varied to according to the position of the print medium  65  in the media advance system  52  and relative to the print zone ( 118  in  FIGS. 3A and 3B ). For example, a first higher vacuum level can be applied to the print medium to generate a higher traction force when the print medium enters the media advance system until it fully covers the print zone, and a second lower vacuum level can be applied to the print medium to generate a lower traction force while the print medium fully covers the print zone. Further, a third or the first higher vacuum level also can be applied to the print medium when the trailing edge of the print medium leaves the print zone. In a state where the lower vacuum level is applied, any media registration error in the X direction can be more readily corrected by a lower tension force applied to the print medium moving across the media advance system. 
       FIG. 6  shows a process flow of an example of a method of feeding a print medium. The method comprises: receiving  80  a print medium by a media advance system; and transporting  82  the print medium by the media advance system to a print zone, such as print zone  118  in  FIGS. 3A and 3B . Transporting comprises applying  84  a first normal force when the print medium is at a first position of the media advance system and applying  86  a second normal force when the print medium is at a second position of the media advance system, wherein the second normal force is different from the first normal force. Applying the first normal force may comprise applying a first vacuum level to the print medium and applying the second normal force may comprise applying a second vacuum level to the print medium wherein the second vacuum level is smaller than the first vacuum level. In the following description, reference is made to the vacuum level with the understanding that the vacuum level creates a normal force or traction force which holds the print medium on the vacuum belts and platen. 
     By varying the vacuum level in response to the position of the print medium in the media advance system, a higher vacuum level can be used in those instances where the print medium is to be flattened and “ironed” to the platen. This is particularly the case in the leading edge and the trailing edge areas of the print medium where a print medium coming from a roll is curled due to the roll shape. Accordingly, in one example, the first higher vacuum level can be applied from the time when the print medium enters the platen of the print media advance system until it fully covers the print zone or reaches the end of the print zone in the media advance direction. In another example, the first higher vacuum level can be applied until the leading edge of the print medium has passed the print zone by a predetermined distance. In a further example, the first higher vacuum level can be applied until the leading edge of the print medium has reached the end of the platen and the print medium fully covers the length of the platen. The second lower vacuum level than can be applied as soon as the leading edge of the print medium fully covers the print zone or has passed print zone by the predetermined distance or fully covers the length of the platen, depending on the condition defined for the first vacuum level. Further, it is possible to again apply the first higher vacuum level or a third higher vacuum level before the trailing edge of the print medium reaches the print zone. In one example, the first higher vacuum level can be applied again from the time when the trailing edge of the print medium reaches the start of the print zone in the media advance direction. In another example, the first higher vacuum level can be applied again when the trailing edge of the print medium is upstream of the print zone by a predetermined distance. In a further example, the first higher vacuum level can be applied again when the trailing edge of the print medium reaches the start of the platen. 
     The first higher vacuum level ensures that the leading edge area and the trailing edge area of the print medium are flattened, with good traction force, on the platen of the media advance system. Once the print medium fully covers the print zone, the traction force can be reduced and the middle part of the print medium, between the leading edge area and the trailing edge area, can still be sufficiently flattened by the combined traction and tension forces applied to the print medium. 
     A certain minimum vacuum level normal force should be maintained to keep the print medium “ironed” all along the plot. The normal force is directly proportional to the pressure drop at the print medium:
 
 F   Normal   =ΔP A   hole   c   a  
 
     With 
     F Normal , normal force; 
     ΔP, pressure drop at print medium; 
     A hole , hole area covered by print medium; 
     c a , influence area coefficient, depends on media air flow permeability. 
     In the same way, the traction force avoids media slippage and it is directly proportional to the pressure drop at the print medium.
 
 F   traction   =μΔP A   hole   c   a   =μF   Normal  
 
     With 
     F traction , traction force; 
     μ, coefficient of friction between vacuum belts and print medium; 
     ΔP, pressure drop at print medium; 
     A hole , hole area covered by print medium; 
     c a , influence area coefficient, depends on media air flow permeability. 
     In general, the pressure drop is lower when the platen is partially covered by the print medium and the impedance of the system is is lower than the nominal impedance value of the media advance system when the platen is fully covered.  FIG. 7  shows a very simple scheme of the impedances of a platen vacuum system partially covered and completely covered by a print medium. In this diagram, the pressure drop P at the print medium corresponds to a voltage; the mass flow of air Q corresponds to a current, and the impedance Z corresponds to a resistance. The impedance Z is a function of media porosity, the number and size of vacuum holes in the platen and the vacuum belts, the air resistance of the ducts and air feed elements or, more generally, any airflow resistance to the vacuum generator. The impedance Z is different in areas covered by the print medium and areas not covered by the print medium. 
     In this example, Z not covered  is the impedance for the system itself, taking into account the geometrical features of the vacuum system (pipes, elbows, pre-chambers, holes, belts hole, etc.). Z covered  includes the same impedance due to all the geometrical features plus the impedance of the print medium. This impedance is different for each print medium depending on its permeability but usually is much higher than the impedance of the media advance system (not covered). These two impedances are changing over time while the print medium moves across the platen. The equivalent impedance of the system when it is not totally covered is: 
     
       
         
           
             
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                           Z 
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                     Z 
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     In order to have a minimum normal force and traction force when the leading edge area and the trailing edge area of the print medium cross the print zone, the first higher vacuum level may be in the range of 80 mmH 2 O to 120 mmH 2 O (about 800 Pa to 1200 Pa), such as at about 80 mmH 2 O (about 800 Pa), 100 mmH 2 O (about 1000 Pa) or 120 mmH 2 O (about 1200 Pa), for example, depending on media type. When the print zone is totally covered, the vacuum level can be lowered to a range of 10 mmH 2 O to 50 mmH 2 O (about 100 Pa to 500 Pa) or about 20 mmH 2 O (about 200 Pa) or about 30 mmH 2 O (about 300 Pa), for example. The first vacuum level may be about twice to about ten times the second vacuum level, or about five times the second vacuum level. When the print zone is fully covered and/or when the platen is fully covered by the print medium, the impedance of the system is relatively high due to the media impedance, so the pressure drop at the print medium is high. Additionally the hole area covered by the print medium, A hole , reaches its maximum value during this state. Accordingly, the vacuum level can be reduced. 
     In one example, at any one point in time, the same vacuum level, either the first vacuum level or the second vacuum level or the third vacuum level, is applied throughout the platen. In another example, the vacuum level may be different in different areas of the platen, e.g. to accommodate different print media widths. The third vacuum level may be provided when the trailing edge of the print medium leaves the print zone wherein the third vacuum level is higher than the second vacuum level and may be the same as the first vacuum level or may be higher or lower than the first vacuum level. 
     Lowering the vacuum level reduces the normal and traction forces, allowing a small media slippage in X direction. Accordingly, the equilibrium between the tension force applied to the print medium in the media advance direction and the traction force applied to the print medium for holding the print medium on the media advance system is reached at a smaller rotation angle and the X axis registration error is reduced accordingly. As a result, the print medium can be fed with a small media bubble in a low position of the bubble sensor to generate an X-direction slippage opposite to the media X movement once the bubble has been consumed in one side of the buffer (see  FIG. 5B ). The media bubble may be smaller than a media bubble size which the bubble sensor is able to measure. Using a smaller bubble size, the buffer that has to be consumed to achieve equilibrium can be brought to a minimum. A bigger media bubble may be generated to allow media cutting without stopping at the end of the plot when the higher vacuum level is applied. By controlling, i.e. increasing and reducing, the vacuum level and bubble size along the plot during the printing operation, the media stabilization point in X direction can be modified. 
     The described concept achieves robustness when feeding a long print medium in a printer, having regard to media position errors in X direction. Even for long print media, having a length of 1 m or more, for example, a stable position in the X direction and a quite small rotation angle of the print medium can be achieved. The absolute X position error can be kept low, minimizing the image position errors, even for very long plots where it is difficult to keep the initial margin of the paper all along the plot. Additionally, the occurrence of wrinkles in the media input area due to the misalignment between the media actual position in the print zone and the feeding position can be mitigated.