Patent Publication Number: US-9849694-B2

Title: Printer encoder adapted for positioning aboard a mobile unit

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application is a continuation of U.S. patent application Ser. No. 11/610,452, filed Dec. 13, 2006, now abandoned which claims the benefit of U.S. Provisional Patent Application No. 60/750,193, filed Dec. 13, 2005, each of which is incorporated by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates generally to a mobile printing and encoding system. More specifically, the present invention relates to a printer and associated RF (“radio frequency”) encoder that is structured and adapted for positioning aboard a mobile unit such as a forklift. 
     Description of the Related Art 
       FIG. 1  depicts a forklift  300  adapted for interrogatting radio frequency identification (“RFID”) transponder equipped articles (not shown) in accordance with the known prior art. The depicted forklift  300  includes a plurality of radio frequency (“RF”) antennas  330  attached to a lifting device  310  of the forklift and are directed toward a loading area  320  of the forklift  300  for interrogating RFID transponder equipped articles that may be lifted or otherwise manipulated by the lifting device  310 . As will be apparent to one of ordinary skill in the art, RFID transponders that are commonly attached to inventory articles have a memory that may contain identification information, article destination information, tracking information, shipping information, billing information, article ownership information, etc. When the forklift  300  picks up an RFID transponder equipped article, or pallet of articles, using its lifting device  330 , an RFID reader (not shown) engages the RF antennas  330  to read any RFID transponders disposed in interrogating proximity to the lifting device  310 . Any information retrieved by the RFID reader may be displayed on user interface  340  disposed in a passenger accessible area  325  aboard the forklift  300  as shown. 
     BRIEF SUMMARY OF THE INVENTION 
     In one embodiment of the present invention, a printer/encoder system is provided and is adapted to be mounted to a mobile unit, such as a forklift-type vehicle. The mobile unit may have a loading area and a passenger accessible area and the printer/encoder system may be mounted proximate to the passenger accessible area. The printer/encoder system is adapted for printing and encoding one or more media units. For example, the printer/encoder system may include an encoder antenna assembly for transmitting electromagnetic energy in order to encode (e.g., read and/or write) a radio frequency transponder associated with the one or more media units. 
     In one embodiment, the printer/encoder system includes a mobile unit mounting system for mounting the printer/encoder system to a mobile unit. The mobile unit mounting system may include a shock resistance system for protecting at least a portion of the printer/encoder system from mechanical shocks or vibrations that are commonly associated with mobile unit movement. 
     The printer/encoder system may include an encoder antenna assembly configured to concentrate electromagnetic energy on a first media unit or a particular portion of a first media unit in an interrogation region of the printer/encoder system. The encoder antenna assembly may be further configured to shield the electromagnetic energy from other media units proximate the first media unit. The printer/encoder system may further include a modular configuration of the encoder assembly that is adapted to allow for easy replacement of encoder components with new or different components, such as different encoder antenna assemblies adapted for different types of media units. 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
       Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
         FIG. 1  is a perspective view of a forklift having an RFID antenna disposed in interrogating proximity to its lifting device in accordance with the known prior art; 
         FIG. 2  is a perspective view of a printer/encoder system installed on an exemplary mobile unit consistent with one embodiment of the present invention; 
         FIG. 3  is a perspective view of a printer/encoder system consistent with one embodiment of the present invention; 
         FIG. 4  is a top view of a printer/encoder system consistent with one embodiment of the present invention; 
         FIG. 5  is a side view of a printer/encoder system consistent with one embodiment of the present invention; 
         FIG. 6  is a front view of a printer/encoder system consistent with one embodiment of the present invention; 
         FIG. 7  is a side view of a printer/encoder system depicting selected hidden components of the media supply system, the encoder electronics system, and the antenna system consistent with one embodiment of the present invention; 
         FIG. 8  is a side view of a printer/encoder system with the antenna housing door in an open configuration for depicting components of the antenna system consistent with one embodiment of the present invention; 
         FIG. 9  is a top view of a printer/encoder system with the antenna housing door in the open configuration to better illustrate selected components of the antenna system consistent with one embodiment of the present invention; 
         FIG. 9A  is a detail view of an exemplary antenna structure provided as part of the antenna system of the printer/encoder system shown in  FIG. 9 , wherein the detail view of  FIG. 9A  is taken from the perspective of arrow  9 A of  FIG. 9 ; and 
         FIG. 10  is a perspective view of a printer/encoder system wherein the media storage bin is detached from the other systems of the printer/encoder consistent with one embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, this invention may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. 
       FIG. 2  depicts a printer/encoder system  100  attached to a mobile unit  50  for printing and encoding media units in accordance with one embodiment of the present invention. For purposes of the foregoing specification and appended claims the term “mobile unit” refers to a truck, cart, or other vehicle that is adapted for inventory control and/or inventory management operations. The foregoing descriptions and associated figures describe an exemplary mobile unit, namely, a forklift type vehicle. Such figures and descriptions are provided merely for illustration purposes and should not be construed as necessarily limiting unless specifically claimed as such. 
     The printer/encoder system  100  illustrated in  FIG. 2  is located in a passenger accessible area  55  of the mobile unit  50  in accordance with one embodiment of the present invention. In this regard, the depicted printer/encoder system  100  is conveniently accessed by an operator. Notably, the depicted positioning differs from prior art RFID transponder equipped mobile unit configurations such as that shown in  FIG. 1  wherein all RF antenna structures  330  are disposed in readable proximity to the loading area  320  of the mobile unit. 
     Printer/encoder systems  100 , such as that illustrated in  FIG. 2 , may, in some embodiments, be configured to communicate with a user interface  60  that is generally mounted in the passenger accessible area  55  of the mobile unit  50 . In various embodiments, for example, the user interface  60  may be used to display information about the printer/encoder system, the media, or information to be printed or encoded on media units that are attachable to an inventory article. The user interface  60  may also be interactive and enable the user to send commands to the printer/encoder system  100 . 
       FIG. 3  illustrates a printer/encoder system  100  structured in accordance with another embodiment of the present invention. For purposes of the foregoing specification and appended claims the term encoder refers to a device adapted to transmit electromagnetic energy into an interrogation zone and thereby read and/or write information to one or more RFID transponders located within the interrogation zone. The foregoing descriptions and associated figures describe an exemplary printer/encoder system. Such figures and descriptions are provided merely for illustration purposes and should not be construed as limiting. 
     Printer/encoder systems in accordance with various embodiments of the present invention are mounted within a passenger accessible area of a mobile unit such as a forklift and are adapted to print visual indicia to one or more media units, read electronic information possibly provided within transponders disposed on or within the media units, and write electronic information to such transponders. In this regard, the printer/encoder system  100  depicted in  FIG. 3  includes a printer/encoder assembly  160 , a bracket assembly  110  for supporting the printer/encoder assembly  160  and attaching the printer/encoder assembly  160  to the mobile unit (not shown), a media supply assembly  130  for storing media units, and a power supply assembly  150  for providing power to the printer/encoder assembly  160 . 
     In the depicted embodiment, the bracket assembly  110  comprises a mobile unit mounting system  112 , a shock resistance system  115 , a power supply mounting system  119 , and a printer/encoder mounting system  117 . The depicted mobile unit mounting system  112  includes base  113  and side brackets  114 . The base  113  and the side brackets  114  may be adapted to receive one or more fasteners (not shown) and used, alone or in combination, for mounting the printer/encoder system  100  to the mobile unit. 
     The depicted shock resistance system  115  is attached to the base  113  and provides a structure for protecting the printer/encoder system  100  from mechanical shocks or vibrations that are commonly associated with mobile unit movement. The shock resistance system may be comprised of springs, rubber mounts, pneumatics, or any other device known in the art for absorbing, dissipating, or reducing the transfer of vibrations and/or forces from one body to another.  FIG. 3  depicts a shock resistance system  115  having four shock mounts  116  that are used to connect the four corners of the printer/encoder mounting system  117  to the base  113 . Notably, only two of the four shock mounts  116  are visible in  FIG. 3 . 
       FIG. 3  depicts an inverted C-shaped bracket as the printer/encoder mounting system  117  in accordance with one embodiment of the present invention. The depicted printer/encoder mounting system  117  includes a first flange  117   a  and a second flange (not shown) defining apertures for receiving fasteners for attaching the printer/encoder mounting system  117  to the shock mounts  116  and base  113 . 
     The depicted power supply mounting system  119  is comprised of a bracket connected to the printer/encoder mounting system  117 . As will be apparent to one of ordinary skill in the art, the inventive concepts of the present invention are not limited to the specific bracket assembly  110  depicted in  FIG. 3 . For example, in one alternative embodiment, the power supply mounting system may be mounted to the base rather than the printer/encoder mounting system as shown. In fact, a variety of mounting structures, brackets, and assemblies of differing material compositions (e.g., polymers, metals, composites, and combinations thereof) may be apparent to one of ordinary skill in the art based upon the mounting area/structures available in the passenger accessible area of the mobile unit. Further, the precise structure (e.g., size, weight, shape, etc.) of the printer/encoder  160  will also play a significant role in selecting the structure and composition of a specific bracket assembly. 
       FIG. 3  further depicts a media supply assembly  130  consistent with one embodiment of the present invention. As depicted, the media supply assembly  130  comprises a media storage bin  132  structured for holding one or more media units  137  comprising a substrate for receiving printed indicia and one or more RFID transponders. For purposes of the present specification and appended claims the term “media unit” shall refer to all types of media that are attachable to an article including lined and linerless labels, tickets, cards, tapes, and other similar materials. 
     The depicted media storage bin  132  includes a hinged media access panel  134 . In this regard, the media access panel  134  opens to allow access to the interior of the media storage bin  132  for loading, changing, viewing, or otherwise accessing the media units  137  contained therein. In other embodiments, the media storage bin  132  may define a cylindrical housing or alternatively, may not define a housing at all and be simply comprised of a spindle for supporting an exposed roll of media units. Notably, the depicted media storage bin  132  is extended to define an integral housing  125  that attaches to the bracket assembly  110  as shown or alternatively, may be provided as a separate unit as described in greater detail with regard to  FIG. 10  below. In the depicted embodiment, the generally rectangular housing  125  is connected to the underside of the C-shaped bracket  117  and thereby obtains the benefit of the shock resistance system  115 . The media supply assembly  130  may be comprised of a variety of materials including metals, polymers, composites, and combinations thereof as will be apparent to one of ordinary skill in the art. 
     As noted above, the media supply assembly  130  is adapted to store, protect, and feed media units  137  to the printer/encoder. The depicted media units  137  are a strip of adhesively backed labels having one or more RFID transponders embedded in each label. The labels are provided on a carrier strip that is folded into a fanfold structure (shown as  138  in  FIG. 7 ) and placed in the media storage bin  132 . The carrier strip is fed between the platen and the printhead of the printer/encoder such that the labels may be may continually drawn from the media supply bin  132  and printed as will be apparent to one of ordinary skill in the art. In alternative embodiments, the media units may be stored in roll form of fed via one or more media feeding/handling devices that are commonly known in the art. For example, if the media  137  is a media supply roll, the media storage bin may be comprised of a cylindrical housing or even just a spindle for holding a media unit supply roll. 
       FIG. 3  also depicts a power supply system  150  in accordance with one embodiment of the present invention. The depicted power supply system  150  is comprised of a power source  152  and power cables  154  and  156 . In the depicted embodiment, the power source  152  is a combination battery and battery charger and is mounted to the power supply mounting system  119 . Alternatively, the power source  152  may comprise a battery alone or a power adapter for connecting to a mobile unit power source (not shown) or an AC power source. Power cables  154  and  156  are used to carry power from the power source  152  to the printer/encoder system  160 . In one embodiment, a single power cable (not shown) may carry all the power necessary for the printer/encoder system  160 . In another embodiment, two power cables  154  and  156  may individually connect the power supply system  150  to the encoder electronics assembly (shown as  190  in  FIG. 7 ) and the printer assembly  170 , respectively. This feature may have a benefit of making it easy to detach the power cords when replacing or servicing various components of the printer/encoder system  100 . 
       FIG. 3  further depicts a printer/encoder assembly  160  in accordance with one embodiment of the present invention. The depicted printer/encoder assembly  160  includes a printer assembly (shown as  170  in  FIG. 7 ) comprising a printhead and a platen roller, an encoder antenna assembly (shown as  180  of  FIG. 8 ), and an encoder electronics assembly (shown as  190  of  FIG. 7 ). The depicted printer/encoder assembly  160  includes a shell or housing  165  for enclosing and protecting various components including the printer assembly, printer electronics, and the like. A variety of known printing systems may be used to print human or machine readable indicia to the media unit substrate. For example, thermal transfer, direct thermal, ink jet, and laser printing systems may be used. Such print systems are well-known in the art and thus are not described in detail here. 
     The shell or housing  165  may take many different configurations without departing from the inventive concepts of the present invention. Preferably, the shell  165  is made of a durable material, such as metal, rubber, polymers, composites, or combinations thereof, for protecting the printer/encoder system components in a warehouse, factory, office, or other similar environment. In various embodiments, the shell  165  may comprise removable or hinged access panels such that one or more of the systems contained within the shell  165  are accessible by a user. 
     In the depicted embodiment, the shell  165  includes an antenna housing portion  167  for enclosing the encoder antenna assembly ( 180  of  FIG. 8 ). The depicted antenna housing portion  167  includes a removable access panel  168   a  for providing access to the encoder antenna assembly as will be apparent to one of ordinary skill in the art. In the depicted embodiment, a cable access hole  169  is defined in the access panel  168   a  for accommodating a cable  181  that electrically connects the encoder antenna assembly ( 180  of  FIG. 8 ) with the encoder electronics assembly ( 190  of  FIG. 7 ). 
       FIG. 4  is a top view of the printer/encoder system  100  of  FIG. 3  consistent with one embodiment of the present invention.  FIG. 4  is shown in order to provide a person skilled in the art with a better understanding of the structure of one embodiment of the invention. Notably,  FIG. 4  illustrates a media exit region  163  defined in the shell  165  of the printer/encoder assembly  160  through which media units  137  exit after printing and/or reading and/or encoding. In other embodiments, the printer/encoder system  100  may further comprise a tear bar  164  or other media detachment system (not shown) for cutting, bursting, or tearing or otherwise separating one or more media units from the remaining media units of the continuous media strip, roll, stack, or ribbon. In other embodiments, a tear bar or media detachment system may not be necessary or even desired depending on the type of media used. For example, such a system may be unnecessary if the media units consist of individual cards or if the strip of media supply had perforations between each label for aiding in separating portions of media without the use of other devices. 
       FIG. 5  is a side view of the printer/encoder system  100  embodiment shown in  FIGS. 3 and 4 .  FIG. 5  is provided in order to illustrate an alternative view of the structure of various selected components of the depicted printer/encoder system  100 . Various components that were shown in  FIG. 3  have been omitted for simplicity, for example, the shock mounts ( 116  of  FIGS. 3, 6, and 10 ) have been omitted so that one may observe the structure of the depicted bracket assembly embodiment. Notably, in the depicted embodiment, a housing divider  126  is provided within the housing  125  for separating the media supply portion of the housing  130  from the portion of the housing that is to containing the encoder electrical assembly ( 190  of  FIG. 7 ). 
       FIG. 6  is a front view of the printer/encoder system  100  depicted in  FIGS. 3, 4, and 5 .  FIG. 6  is shown in order to provide a person skilled in the art with a better understanding of this one embodiment of the invention. Thus,  FIG. 6  is for illustration purposes and should not be construed as limiting. Besides showing front views of many of the systems and assemblies described above,  FIG. 6  further illustrates a user interface  175  for the printer/encoder system provided a front portion of the shell  165  in accordance with one embodiment of the invention. As depicted by  FIG. 6 , the user interface  175  may comprise a display  176 , such as a liquid crystal display (LCD), and may further comprise at least one key or button  177  for enabling a user to input information and/or engage one or more components of the printer/encoder system  160 . In other embodiments of the present invention, the user interface  175  may be located in other locations on the printer/encoder system  100 . In addition to, or as an alternative to, the user interface  175 , a separate user interface may be located apart from the printer/encoder system  100 . For example, as described above,  FIG. 2  shows an embodiment of the present invention where a separate user interface is located in a passenger accessible area of the mobile unit  50 . Such user interfaces may be adapted to drive the printer/encoder system  100  of various embodiments of the present invention as will be apparent to one of ordinary skill in the art. 
       FIG. 7  is a side view illustrating in dashed lines various components enclosed within the printer/encoder system  100  embodiment depicted in  FIGS. 3, 4, 5 , and  6 . For example,  FIG. 7  depicts, in dashed lines, a printer assembly  170 , an encoder antenna assembly  180  including an encoder antenna casing  182 , an encoder electronics assembly  190 , and a media unit supply  138 . The depicted antenna casing  182  is enclosed within the antenna housing portion  167  of the shell  165 . As described above, the encoder antenna is electrically connected to and driven by the encoder electronics assembly  190 . In the depicted embodiment, the encoder electronics assembly  190  is located proximate one end of the housing  125  as shown. In various embodiments, the encoder electronics end of the housing  125  is integral to or attached to the under side of the inverted C-shaped bracket  117  as shown. In this regard, the encoder electronics assembly  190  obtains the benefit of the shock resistance system described above. 
     In the depicted embodiment, the media supply  138  is stored at a second end of the housing  125  as shown. As noted above, the depicted media supply  138  is provided in a fanfold arrangement merely for illustration purposes and multiple additional media storage configurations may be used. 
     It may be notable from the embodiment depicted in  FIG. 7  that the encoder electronics assembly  190  is located exterior to the printer/encoder shell  165  and connected to the encoder antenna assembly  182  by one or more cables. In this regard, a modular arrangement is provided whereby the type (e.g., UHF, HF, etc), size, and structure of the encoder electronics may be changed depending upon the application. Further, the encoder electronics may be readily serviced or replaced without opening the printer/encoder shell  165  and thereby potentially introducing dirt, moisture, or other print degrading contaminants into the printer system. 
       FIG. 8  shows the side view of the printer/encoder system as shown in  FIG. 7  except that the hinged antenna access panel  168  is shown in the open configuration. This configuration more clearly shows the antenna casing  182  located within the antenna housing  167 .  FIG. 8  shows an antenna casing  182  configured in a half cylinder-like configuration for fitting into a similar-shaped cavity defined for receiving the antenna casing. In various embodiments of the present invention, the antenna casing  182  is structured to concentrate electromagnetic energy transmitted by the antenna on a given media unit and also potentially shield such electromagnetic energy from other media units. In this regard, the antenna casing may be comprised of metal or other similar surfaces that are structured to limit passage of electromagnetic energy. 
     In one embodiment, the antenna casing  182  defines a media adjacent surface  183  that is adapted for positioning adjacent a media unit intended for encoding (i.e., reading, writing, etc.). The media adjacent surface may define an interrogation window through which electromagnetic energy may be transmitted. In one embodiment, as will be described in greater detail below with respect to  FIGS. 9 and 9A , the interrogation window may receive a protective polymer shield that prevents against ingress of dirt, moisture, and other contaminants while allowing the passage of electromagnetic energy transmitted by the antenna assembly. 
       FIG. 9  shows the top view of the printer/encoder system as shown in  FIG. 8  with the hinged antenna access panel  168  is shown in the open configuration. This configuration more clearly shows the antenna casing  182  located within the antenna housing portion  167 . Cable  181 , which electrically connects the encoder electronics assembly  190  with the encoder antenna assembly  180 , is illustrated connecting to one side of the antenna casing  182  via cable connector  181   a . As noted above, having the encoder electronic assembly  190  located separate from the encoder antenna assembly  180 , and easily detachable from each other and from the printer/encoder system  100 , may have the advantage of allowing for easier interchangeability of encoder antennas and/or encoder electronic assemblies. More specifically, in one embodiment, different antenna assemblies, having different antenna types, sizes, and/or configurations, may be replaceably provided for tailoring the antenna structure to a particular size, length, or shape of media unit. Further, such differing antenna structures may be provided to interrogate differing transponder locations on a given media unit. In one embodiment of the present invention, the antenna assembly  180  can be changed without changing the electronic assembly  190  that drives the antenna assembly. In other embodiments, the electrical assembly  190  and the antenna assembly  180  may be able to be serviced individually. 
       FIG. 9A  shows a top view of an exemplary antenna structure  182   a  provided on an antenna assembly housed within an antenna casing in accordance with one embodiment of the present invention. The depicted antenna structure  182   a  may be visible through the interrogation window defined in the media adjacent surface of the antenna casing along Arrow  9 A as shown in  FIG. 9 . The depicted antenna structure  182   a  includes a printed circuit board (PCB)  185  for supporting an input port  187 , a conductor  188 , and terminating load  189 . Each of these components are provided in electrical communication as will be apparent to one of ordinary skill in the art. The input port  187  may be connected to the encoder electronics assembly  190  via the cable  181  and the terminating load  189  may be connected to the encoder electronics assembly  190  via the conductor  188  and the cable  181 . The specific design and configuration of the conductor  188  dictates at least some elements of the performance of the antenna. As such, a person skilled in the art may use many different RF antennas (e.g., a half-wavelength transmission line, a microstrip, or a coplanar transmission line coupler) to achieve various embodiments of the present invention. The antenna depicted in  FIG. 9A  is an antenna in a “bow tie” conductor configuration that allows for increased bandwidth, thereby allowing for antennas having a smaller overall length, which may be advantageous in some embodiments of the present invention. Of course, the antenna assembly embodiments depicted in  FIGS. 9 and 9A  are for illustration purposes and multiple non-resonant antenna structures may be used. 
       FIG. 10  is a perspective view of another embodiment of the printer/encoder system  100  of the present invention. The depicted embodiment comprises all of the printer/encoder system components as described above for the other embodiments; however, the media supply assembly  130  in this embodiment is not rigidly attached to the bracket assembly of the printer/encoder system  100 . In this embodiment, the media supply assembly may be attached directly to the mobile unit and located remotely from the bracket assembly. This embodiment may, in fact, be preferable in some applications as rigid attachment of the media storage bin to the bracket assembly may provide undue weight or strain on the bracket assembly. The media supply assembly may be mounted in any number of configurations without departing from the inventive concepts of the present invention. 
     In one embodiment of the present invention, the printer encoder system  100  is adapted to communicate wirelessly or by a wired connection with one or more servers other electronic devices via a communication network. For example, the printer/encoder system  100  may include a wireless transceiver that allows the printer/encoder to communicate information to and/or from an inventory management system via, for example, a wireless local area network (WLAN). The printer/encoder system  100  may be configured to synchronize automatically with the other device or may be configured to communicate with the other device when instructed to do so by a user of the printer/encoder system  100  or by a user of the other device. 
     In another embodiment of the present invention, the printer/encoder system  100  is adapted to communicate with one or more RF antennas located apart from the printer/encoder system  100 , such as an RF antenna located proximate the loading area of the mobile unit  50 . For example, the printer/encoder system  100  may be configured to communicate, wirelessly or by a wired connection, with one or more of the RF antennas  330  of the prior art system illustrated in  FIG. 1 . In this regard, in one embodiment, the mobile unit  50  may have a RF antenna located proximate the loading area for reading information from a RFID tag associated with a pallet of articles in the loading area. The printer/encoder system  100  may be able to communicate with the RF antenna to receive the RFID tag information and may then use this information to print and/or encode one or more media units. 
     Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.