Patent Publication Number: US-2019186894-A1

Title: Width detecting media hanger

Description:
FIELD OF THE INVENTION 
     The present invention relates to a printer, and more specifically, to a printer media hanger that detects a media width. 
     BACKGROUND 
     Generally, the thermal printing industry suffers from a reliable method of detecting media or ribbon width that is both accurate and automatic. Conventional methods require user intervention where the user must adjust one or more guides on the sides of the media, and an approximate media width is determined from the distance between the guides. 
     A method and device that accurately determines a media width without requiring user input would increase the productivity of the thermal printer and the precision of the printing process. 
     SUMMARY 
     An embodiment of a printer comprises a processor; a media hanger comprising a sensor array receiving space extending along a length of the media hanger; and a sensor array positioned in the sensor array receiving space and communicatively connected to the processor, the sensory array comprising a plurality of sensor pairs, each sensor pair having an emitter and a receiver, the sensor array being configured to: emit light from the emitter outward from the media hanger, detect the emitted light after the emitted light is reflected off a surface of media loaded on the media hanger, transmit signal intensity of the reflected light detected by each of the sensor pairs to the processor; wherein the processor is configured to determine a width of the media loaded on the media hanger based on the signal intensity detected by each of the sensor pairs. 
     In an embodiment, the emitter emits infra-red light, and the receiver detect infra-red light. 
     In an embodiment, each of the sensor pairs is spaced a known distance from adjacent sensor pairs. 
     In another embodiment, each of the sensor pairs are positioned an equidistance apart from the adjacent sensor pairs. 
     In yet another embodiment, increasing a number of sensor pairs along the length of the media hanger correspondingly increases a measurement precision of the loaded media width. 
     In an embodiment, the sensor pairs located proximate to the surface of the loaded media will have a high signal intensity of reflected light and sensor pairs located distal to the surface of the loaded medium with have a low signal intensity of reflected light. 
     In another embodiment, the width of the media is determined by summing a first total spacing length of sensor pairs having the high signal intensity. 
     In another embodiment, a group of the sensor pairs located proximate to an edge of the loaded media will have a signal intensity that transitions from the high signal intensity to the low signal intensity. 
     In an embodiment, a transparent window covers the sensor array receiving space. 
     In another embodiment, light from the emitter is emitted at a known frequency, and the window is a bandpass filter that blocks light having frequencies outside the known frequency while passing light having the known frequency. 
     In an embodiment, a method comprises: emitting light from an emitter in a direction outward from a media hanger towards media loaded on the media hanger, the emitted light being generated by a plurality of sensor pairs, each sensor pair comprising the emitter and a receiver; detecting the emitted light with the receiver after the emitted light has been reflected off a surface of the loaded media; transmitting a signal intensity of the emitted light detected by the receiver in each of the sensor pairs to a processor, the receiver from each sensor pair detecting light emitted from the corresponding emitter in the sensor pair; and processing the signal intensities detected by the receiver from each sensor pair to determine a width of the loaded media. 
     In an embodiment, each of the sensor pairs are positioned an equidistance apart from the adjacent sensor pairs. 
     In another embodiment, the sensor pairs located proximate to the surface of the loaded media will have a high signal intensity of reflected light and sensor pairs located distal to the surface of the loaded medium with have a low signal intensity of reflected light. 
     In yet another embodiment, the width of the media is determined by summing a first total spacing length of sensor pairs having the high signal intensity. 
     In an embodiment, a group of the sensor pairs located proximate to an edge of the loaded media will have a signal intensity that transitions from the high signal intensity to the low signal intensity. 
     In an embodiment, a media hanger assembly comprises: a processor; a body comprising a sensor array receiving space extending along a length of the body, and a light passing window extending along the length of the body; and a sensor array positioned in the sensor array receiving space and communicatively coupled to the processor, the sensory array comprising a plurality of sensor pairs, each sensor pair having an emitter and a receiver, the sensor array being configured to: emit light from the emitter outward from the media hanger, detect the emitted light after the emitted light is reflected off a surface of media loaded on the body, transmit signal intensity of the reflected light detected by each of the sensor pairs to the processor; wherein the processor is configured to determine a width of the media loaded on the body based on the signal intensity detected by each of the sensor pairs. 
     In an embodiment, each of the sensor pairs are positioned an equidistance apart from the adjacent sensor pairs. 
     In another embodiment, the sensor pairs located proximate to the surface of the loaded media will have a high signal intensity of reflected light and sensor pairs located distal to the surface of the loaded medium with have a low signal intensity of reflected light. 
     In another embodiment, the width of the media is determined by summing a first total spacing length of sensor pairs having the high signal intensity. 
     In an embodiment, a group of the sensor pairs located proximate to an edge of the loaded media will have a signal intensity that transitions from the high signal intensity to the low signal intensity. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The invention will now be described by way of example with reference to the accompanying Figures, of which: 
         FIG. 1  is a plan view of a conventional printer with a conventional media hanger; 
         FIG. 2  is a plan view of a printer having a media hanger with a sensor array in the absence of any media; 
         FIG. 3  is a plan view of the printer having media loaded on the media hanger of  FIG. 2 ; 
         FIG. 4  is a cross-sectional view of emitted and reflect light from the sensor array when the media hanger is loaded with a roll of media; 
         FIG. 5  is a cross-sectional view of emitted light from the sensor array when the media hanger is not loaded with a roll of media; 
         FIG. 6  is a schematic view of a processor connected to the sensor pairs in the sensor array; 
         FIG. 7  is a block diagram of a method of determining a width of media loaded on the media hanger; and 
         FIG. 8  is a plan view of a media cap connected to the media hanger. 
     
    
    
     DETAILED DESCRIPTION 
     The following description is based on applications supporting a variety of types of media. The media may include, but not limited to, ribbon, paper, labels and tickets. The term “media/ribbon”, as used herein, refers to the variety of types of media. The term “media/ribbon” may also be referred to as a “roll of media/ribbon”. Also “media/ribbon” is equivalent to “media or ribbon”. A media hanger of a printer supports the media or ribbon. 
       FIG. 1  shows a typical printer  40  with a conventional media hanger  50 . The conventional media hanger  50  generally has an elongated shape, upon which a roll of media can by loaded up by inserting the media hanger  50  through a hollow core positioned in the center of the roll of media. 
     As shown in  FIGS. 2-6 , a printer  1  comprises a media hanger  100 , a sensor array  200 , and a processor  300 . 
     The media hanger  100  comprises a body  110 , a sensor array receiving space  120 , and a light passing opening  130 . The body  110  has a first end  111 , an opposite second end  112 , and an outer surface  113 . 
     The sensor array receiving space  120  is positioned along a length of the body  110 . In an embodiment, the sensor array receiving space  120  is positioned along the entire length of the media hanger body  110 . In another embodiment, the sensor array receiving space  120  positioned along a portion of the media hanger body  110 . The sensor array receiving space  120  is positioned within the body  110  to form a groove-like shape having a sensor-mounting surface  121 , two opposing sidewalls extending along the length of the sensor array receiving space  120 , and two opposing endwalls  122   a , 122   b  into which the opposing sidewalls connect. The sidewalls and the endwalls  122   a , 122   b  extend orthogonally outward from the sensor-mounting surface  121  towards the outer surface  113  of the body  110 . 
     The light passing opening  130  is positioned in the outer surface  113  of the body  110 . The light passing opening  130  is correspondingly positioned over the sensor array receiving space  120 . Light can be emitted outward or received in the sensor array receiving space  120  through the light passing opening  130 . 
     In an embodiment shown in  FIGS. 2-5 , a light passing window  140  is positioned over the light passing opening  130 . The light passing window  140  can be made of a transparent material such as a plastic or glass, or can be made of a material that acts as a bandpass filter that passing light having a frequency within the bandpass frequency range, and blocks light having frequencies outside the bandpass frequency. In an embodiment, the light passing window  140  can be transparent, and a band pass filter can be installed or applied over the light passing window  140 . 
     As shown in the embodiments of  FIGS. 2-5 , the sensor array  200  comprises a plurality of sensor pairs  210 , each sensor pair having an emitter  211  and a receiver  212 . The emitter  211  emits light in a known frequency range, and the receiver  212  detects light in the known frequency range. In an embodiment, the emitter  211  emits light in the infra-red range, and the receiver  212  detects light in infra-red light. In other embodiments, the emitter  211  emits visible light, and the receiver  212  detects visible light. In an embodiment, the emitter  211  is a light emitting diode (LED). The receiver  212  can be a photodiode or phototransistor that absorbs light frequencies emitted by the LED  211 . Further, as described above, when the emitter  211  emits light in a known frequency range, such as infra-red, the light passing window  140  can be a band pass filter that permits the emitted infra-red light to pass, but blocks light that is outside of the infra-red frequency range (e.g. ambient light). 
     As shown in  FIGS. 4 and 5 , the emitter  211  transmits light outward towards media installed on the media hanger  100 . The transmitted light reflects off the core of the media, and the reflected light RL is received by the receiver  212  (See  FIG. 4 ). In embodiments where the media does not have a separate core, the transmitted light reflects off the media itself, and the reflected light RL is received by the receiver  212 . If the installed media has a width that is less than a width of the media hanger  100 , a portion of the sensor pairs  210  will not have any of the installed media over them. For those uncovered sensor pairs  210 , light emitted from their corresponding emitters  211  will not be reflected back to the corresponding receivers  212 , e.g.  FIG. 4  where the sensor pairs  200  proximate to the first end  122   a  of the media hanger  100  are not covered by the loaded media, so no reflected light RL is received; and  FIG. 5  where no reflected light RL is received by any of the receivers  212 . Thus, the receivers  212  of the uncovered sensor pairs  210  will have a lower signal intensity compared to the receivers  212  of the covered sensors pairs  210  that receive reflected light RL. A high signal intensity refers to a signal which has the same value as a sensor power voltage (e.g. “VCC”). A low signal intensity may refer to a signal close to the ground level (e.g., 0V) or with a value of −VCC, which is opposite the sensor power voltage. For example, values may be a high signal intensity equals 5V (or 3.3V) and low signal intensity may equal 0V. However, those of ordinary skill in the art would recognize that such power voltage values are illustrative, not definitive, and that these values will vary based on the exact types of receivers and emitters employed. 
     Each of the sensor pairs  210  is spaced a known distance from adjacent sensor pairs  210 . In an embodiment, each of the sensor pairs  210  is positioned an equidistance apart from the adjacent sensor pairs  210 . In another embodiment, each of the sensor pairs  210  is positioned apart at known, but unequal distances. For example, the density of sensor pairs  210  can vary along the length of the sensory array, where areas that correspond to common media widths will have a higher number of sensor pairs  210  (e.g. higher density) in that region that in areas that do not correspond to common media widths. 
     The number of sensor pairs  210  in the sensor array  200  can vary, wherein increasing a number of sensor pairs along a fixed length correspondingly increases a measurement precision when measuring a width of media loaded on the media hanger  100 . For example, each sensor pair  210  can be positioned one sixteenth of an inch from adjacent sensor pairs  210 , one eighth of an inch from adjacent sensor pairs  210 , one quarter of an inch from adjacent sensor pairs  210 , or any other spacing depending on the level of precision desired. 
     In other embodiments, the sensor array  200  comprises a contact image sensor (“CIS”) extending the length of the sensor array receiving space  120 . 
     In another embodiment (not shown), the sensor array  200  comprises a plurality of receivers  212  without any corresponding emitters  211 . In principle, this embodiment operates the opposite of the emitter/receiver pair embodiment, because the receivers receive either ambient light or an externally positioned emitter. For example, when media is installed on the media hanger  100 , a portion of the receivers  212  is covered by the installed media and does not receive any light. Those covered receivers  212  would therefore have low signal intensity. However, the other portion of the receivers  212  would not be covered by the installed media, and would receive and detect either ambient light or light emitted from an externally positioned emitter. Those uncovered receivers  212  would therefore have high signal intensity relative to the covered receivers  212 . The term externally positioned emitter refers an emitter that is positioned away from the sensor array  200 , such as an LED positioned in a printer cover, etc. Determining a width of the installed media would be calculated in an opposite manner than the method used to calculate width in the emitter/receiver pair embodiment. 
     In an embodiment shown in  FIG. 6 , the processor  300  (e.g. a central processing unit) is electronic circuitry within the printer or an externally connected computer that carries out the instructions of a computer program by performing the basic arithmetic, logical, control and input/output (I/O) operations specified by the instructions as hereinafter described communicatively coupled to the sensor array  200 . The processor  300  is communicatively coupled to a memory  310 , which stores the computer program having instructions in accordance with the various embodiments discussed herein, to control the emitters  211 , to receive and process signal information from the receivers  212 , and determine a width of media loaded on the body  110  based on the signal intensity detected by each of the sensor pairs  210 . 
     Assembly of the major components of the printer will now be described with reference to  FIGS. 2-6 . The media hanger  100  is positioned within a housing  10  of the printer  1 . The sensor array receiving space  120  extends along a length of media hanger  100 , and the light passing opening  130  is formed in the outer surface  113  of the media hanger  100 , providing a through-hole to the sensor array receiving space  120 . The sensory array  200  is positioned on the sensor-mounting surface  121 , with the emitters  211  and receivers  212  facing away from the sensor-mounting surface  121  and towards the light passing opening  130 . The light passing window  140  is positioned over the light passing opening  130  and is flush with the outer surface  113  of the media hanger  100 , although in other embodiments the light passing window  140  can be position above or below the outer surface  113 . 
     A method  400  of determining a width of media installed on the media hanger  100  is described with reference to  FIG. 7 . The method  400  comprises emitting light from an emitter  211  in a direction outward from a media hanger  100  towards media loaded on the media hanger  100  at block  410 , the emitted light being generated by a plurality of sensor pairs  210 , each sensor pair  210  comprising the emitter  211  and a receiver  212 ; detecting the emitted light with the receiver  212  after the emitted light has been reflected off a surface of the loaded media at block  420 ; transmitting a signal intensity of the emitted light detected by the receiver  212  in each of the sensor pairs  210  to a processor  300 , the receiver  212  from each sensor pair  210  detecting light emitted from the corresponding emitter  211  in the sensor pair  210  at block  430 ; and processing the signal intensities detected by the receiver  212  from each sensor pair  210  to determine a width of the loaded media at block  440 . 
     The processing step at block  440  is based on the following principle: the sensor pairs  210  located proximate to the surface of the loaded media will have a high signal intensity of reflected light and sensor pairs  210  located distal to the surface of the loaded medium with have a low signal intensity of reflected light. The width of the loaded media is determined by summing a total spacing length of sensor pairs  210  having the high signal intensity. Stated differently, since the distance between each sensor pair  210  is known, the distance between sensors pairs  210  having a high signal intensity of reflected light can be determined by adding the total distance between all of the sensor pairs  210  having the high signal intensity. 
     In an embodiment, an edge of the loaded media can be determined by identifying a transition of high signal intensity to low signal intensity in a group of the sensor pairs  210  located proximate to an edge of the loaded media. For example, as shown in  FIG. 4 , sensor pairs  210  covered by the loaded media with have a high signal intensity, whereas sensor pairs  210  having a low signal intensity will not be covered by the loaded media. However, sensor pairs  210  positioned along an edge of the loaded media will only receive a portion of emitted light, because the loaded media will only reflect that portion of emitted light back towards the receiver  212 , while the remaining portion will not be reflected. The resultant signal intensity detected by the receiver  212  will be more than the low signal intensity, but less than the high signal intensity (i.e. a medium signal intensity), forming an identifiable transition from the high signal intensity to the low signal intensity. By identifying this transition, the edge of the loaded media can be determined. 
     In an embodiment, when the printer  1  uses a media cap to secure loaded media on the media hanger  100 , the edge of the loaded media can be determined by detecting the transition from high to low signal marking the width of the media (as previously described) plus the width of the media cap, and subtracting a known width of the media cap from the measured width. The media cap may also be known as an “end cap” or a “media retaining cap”. 
     In an embodiment shown in  FIG. 8 , the media cap  15  includes media cap body  16  having a securing end  16   a  and a free end  16   b . The securing end  16   a  connects the media cap  15  to the media hanger  100 . A light-passing space  17  is formed in the media cap body  16  at the securing end  16   a . In practice, light emitted from the emitters  211  will pass through the light-passing space  17  and will not be reflected back to the receiver  212 , as would occur when using a media cap without the light passing space  17  (as previously described). In this embodiment, the loaded media width will be determined in the same manner as previously described for embodiments that do not use a media cap  15 , e.g. the step of subtracting the width dimension of the media cap  15  is omitted. 
     To supplement the present disclosure, this application incorporates entirely by reference the following patents, patent application publications, and patent applications:
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     In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.