Patent Document

FIELD OF THE INVENTION 
   The present invention relates, in general, to printing devices, and, more particularly, to stapler/stackers in printing devices. 
   DESCRIPTION OF RELATED ART 
   With advancements in printing technology, many features and elements of printing, which formerly were only available on large-scaled, expensive printers, are now available on desktop printing models. Two such features are stapling and offset stacking. Stapling is generally implemented by incorporating a stapler into the printer. Print jobs that are designated for stapling are typically re-routed to a path that feeds a stacker or collection area in proximity to the stapler and, which accumulates the pages and then staples the completed copy. 
   Offset stacked print jobs are typically used with or without stapling to stack one complete copy or print job on top of another complete copy or print job with a slight offset in the output bin in order to make separating the copies easier for the user. Alternatively, instead of placing a complete copy or print job offset against subsequent copies, all copies of each page may be offset against one another. Again, print jobs designated for offset stacking are typically re-routed to a path that facilitates collecting or accumulating all of the pages of the copy job and then outputting the copy through offset joggers that will systematically allow each separate copy to be placed in the output bin on top of the previous copy with a slight physical offset. Joggers are generally sets of arms in printing systems that typically hold the print media on each edge. The arms can sometimes translate from side-to-side in order to offset the particular print or copy job. Joggers also may typically move closer and further apart to accommodate various media widths. Because both features, stapling and offset stacking, generally use a stacker to collect or accumulate all of the pages of a copy set before either stapling or offsetting, these features have generally been combined into a stapler/stacker in the different printing configurations. 
   Before examining such example printer configurations, it may be helpful to address one basic operation arrangement of a typical laser printer.  FIG. 1  is a schematic diagram of one embodiment of a laser printer, designated by reference number  101 . In general, and referring to  FIG. 1 , a computer transmits data representing an image to input port  102  of printer  101 . This data is analyzed in formatter  103 . Formatter  103  may include a microprocessor, a related programmable memory and a page buffer. Formatter  103  formulates and stores an electronic representation of each page to be printed. Once a page has been formatted, the electronic representation of each page may be transmitted to the page buffer. The page buffer breaks the electronic page into a series of lines one dot wide. This line of data is sent to the printer controller  104 . Controller  104 , which also preferably includes a microprocessor and programmable memory, drives laser  105  and controls the drive motor or motors, fuser temperature and pressure, and the other print engine components and operating parameters. 
   Each line of data is used to modulate the light beam produced by laser  105 . The light beam is reflected off a multifaceted spinning mirror  106 . As each facet of mirror  106  spins through the light beam, it reflects or “scans” the beam across the side of a photoconductive drum  107 . Photoconductive drum  107  rotates just enough that each successive scan of the light beam is recorded on drum  107  immediately after the previous scan. In this manner, each line of data is recorded on photoconductive drum  107 . Toner is electrostatically transferred from developing roller  109  onto photoconductive drum  107  according to the data previously recorded on the drum. The toner is thereafter transferred from photoconductive drum  107  onto media  110  (e.g., paper) as media  110  passes between drum  107  and pressure roller  111 . Drum  107  is cleaned of excess toner with cleaning blade  113 . Drum  107  may be completely discharged by discharge lamps  114  before a uniform charge is restored to drum  107  by charging roller  108  in preparation for the next toner transfer. 
   Each sheet of media  110  is advanced to the photoconductive drum  107  by a pick/feed mechanism  116 . Pick/feed mechanism  116  includes motor driven feed roller  117  and registration rollers  122 . A paper stack  118  is positioned in input tray  119  to allow sliding passage of the top sheet of media  110  into pick/feed area  115  at the urging of feed roller  117 . In contacts the upper surface of media  110  and pulls it into pick/feed area  115 . As the leading edge of media  110  moves through pick/feed area  115 , it is engaged between the pair of registration rollers  122 . A ramp  123  helps guide media  110  into registration rollers  122 . Registration rollers  122  advance media  110  along the media travel path  120  until it is engaged between drum  107  and pressure roller  111  where toner is applied to the paper as described above. 
   Once the toner is applied to media  110 , it is advanced along the paper path to fuser  112 . Fuser  112  includes a heated fusing roller  124  and a pressure roller  125 . As the paper passes between the rollers, toner is fused to the paper through a process of heat and pressure. Heated fusing roller  124  is heated by heating element  126 . 
   Returning to one particular printer configuration, a front-oriented, front access, face-down media output pathway from the user, and a fusing system with media flipper located in the top-front portion of the printer (FOFAP), several different combined stapler/stacker system implementations have been attempted.  FIG. 2  is a side view of FOFAP  20  with front-mounted print system  206 , fuser  201 , and stapler/stacker  203 . In this embodiment of FOFAP  20 , on print activation, the paper follows main paper path  200  to print system  206  and then fuser  201 . In regular printing jobs, the final print product is output into main high-capacity (HiCap) output bin  202 . However, when a staple function or offset function is selected, the paper is re-directed into stapler/stacker assembly  203 . The collection of pages of the print job takes place in stapler/stacker assembly  203  until all pages are collected. Once collected, the job is either stapled or offset, depending on the feature selected, and output onto stapler/stacker output tray  205  via joggers  204 . 
   The configuration of the front-mounted flipper and stapler/stacker shown for FOFAP  20  generally requires either that the user access the output from the side of the printer, which causes a usability issue, or that the printer be oriented sideways, which typically costs more and takes up more space on a desktop. Furthermore, stapler/stacker assembly  203  with joggers  204  and stapled/offset output tray  205  generally blocks front and top access to main HiCap output bin  202  and also may block access to any access doors for maintenance. This configuration of stapler/stacker assembly  203  also adds significant height to FOFAP  20 . 
     FIG. 3  is a side-view of FOFAP  30  configured with front-mounted printing apparatus  307 , fuser  301 , rear-mounted flipper  303 , and rear-mounted stapler/stacker assembly  304 . In operation, paper is fed along main paper path  300  through print mechanism  307  and fuser  301 . In normal print jobs, the printed product is output onto primary output bin  302 . If either the staple or offset feature is utilized, fuser  301  instead directs the paper to flipper  303  to be flipped into stapler/stacker  304 , in order to maintain the face-down output orientation of the stapled or offset product. The pages of the print job are collected in stapler/stacker  304  during the printing process. As the copy is completed, stapler/stacker either staples or offsets the output copy onto joggers  305  to correctly place the stapled or offset printed copy onto offset output bin  306  in a face-down orientation. 
   The configuration of FOFAP  30  generally requires an additional media flipper, flipper  303 , to achieve face-down stacking due to the shape of the paper path. Furthermore, rear-mounted stapler/stacker  304  generally adds significant height to FOFAP  30 . The depth of FOFAP  30  would also likely require an increase in order to facilitate use of longer sized papers, such as legal, A4, and the like, due to the positioning of rear-mounted stapler/stacker  304 . Because stapler/stacker  304  lies at the end of primary output bin  302 , the leading edge of output pages may impact stapler/stacker  304  causing buckling or bending of the output media. Moreover, even if primary output bin  302  was long or deep enough, the output to primary output bin  302  and offset output bin  306  would be facing different directions, which may be non-intuitive to a user, thus, causing confusion. Also, because of the placement of flipper  303  and stapler/stacker  304  in relation to fuser  301  is relatively far, there is likely to be reduced performance for first-page-out time in addition to reduced overall performance (speed) for all jobs. Moreover, because each page typically has to wait for each previous page to be completely turned over in flipper  303 , performance is further slowed. 
   BRIEF SUMMARY OF THE INVENTION 
   Representative embodiments of the present invention are directed to a front-oriented, front-access printer (FOFAP), the FOFAP configured with a front-mounted fuser, the FOFAP comprising a print mechanism, a main paper path passing through both the print mechanism and the fuser, a media flipper for directing the paper into a second path, a stapler/stacker mounted in proximity to the front-mounted fuser, and a redirector within the front-mounted fuser for redirecting the paper from the second path to the stapler/stacker in response to selection of a staple/stacking feature. 
   Further representative embodiments of the present invention are directed to a method for redirecting print media to a front-mounted stapler/stacker assembly in a front-oriented, front-access printer (FOFAP) having a front-mounted fusing apparatus, the method comprising directing the print media through a print system, guiding the print media through a fusing apparatus after the print system, and re-directing the print media from an alternative path to the front-mounted stapler/stacker assembly using an existing media flipper for the alternative path, the re-directing being responsive to receiving a signal to perform a staple/offset function. 
   Additional representative embodiments of the present invention are directed to a printer having staple/offset stack features, the printer being front-oriented, front-access oriented, the printer comprising printing means, fusing means mounted in a front area of the printer, media flipping means for directing the print media into a second printing path, stacking means mounted in a front side of the printer for accumulating the print media pending execution of a staple/offset function, and redirection means utilizing the media flipping means to deflect the print media into the stacking means in response to selection of the staple/offset stack capability. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a schematic diagram of one embodiment of a laser printing system; 
       FIG. 2  is a side view of a FOFAP with a top-front mounted fuser and a stapler/stacker; 
       FIG. 3  is a side-view of a FOFAP configured with a front-mounted fuser and a rear-mounted flipper and stapler/stacker assembly; 
       FIG. 4  is a side view of one embodiment of a FOFAP configured with a front-mounted fusing system and a front mounted stapler/stacker integrated into the top front portion of the FOFAP; 
       FIG. 5A  is a diagram detailing a diverting system for a FOFAP, as shown in  FIG. 4 ; 
       FIG. 5B  is a diagram detailing an open diverting system of a FOFAP, as shown in  FIG. 4 ; 
       FIG. 6A  is a diagram detailing an alternative embodiment of a diverting system for a FOFAP, as shown in  FIG. 4 ; 
       FIG. 6B  is a diagram detailing an open diverting system of a FOFAP, as shown in  FIG. 4 ; and 
       FIG. 7  is a side view of another embodiment of a FOFAP configured with front-mounted color print mechanisms and a front-mounted fusing system. 
   

   DETAILED DESCRIPTION 
     FIG. 4  is a side view of one embodiment of FOFAP  40  configured with front-mounted print mechanism  406 , front-mounted fusing system  401 , and front-mounted stapler/stacker  404  integrated into the top front portion of FOFAP  40 . In operation, pages that are to be stapled or offset are directed from main paper path  400  to stapler/stacker device  404  by redirecting the pages using media flipper  403 . Media flipper  403  exists originally in FOFAP  40  for duplex printing. When the staple/offset printing feature is selected the paper begins exiting through media flipper  403 . However, when the trailing edge of the paper exits fuser  401 , media flipper  403  reverses direction, pulling the paper back into FOFAP  40 . Instead of directing the paper into duplex paper path  407 , the page is directed into stapler/stacker  404 . Pages are accumulated in stapler/stacker device  404  until the copy is complete. Depending on the operation selected the copy is either stapled or offset into folding offset output tray  405 . Folding offset output tray  405  does not obscure primary output  402  and may be folded away by the user, decreasing the effective footprint of FOFAP  40 . 
   The staple/offset path through stapler/stacker device  404  is essentially unaltered from main paper path  400  except for the diversion through existing media flipper  403  of the duplexing system. There is no efficiency penalty for non-offset/stapled jobs because they generally do not deviate form the original paper path. As such, there is little effect on first page out time for stapled/offset print jobs. Additionally, unlike the existing configurations, the embodiment shown in  FIG. 3  uses the existing media flipping capabilities of FOFAP  40  which reduces the costs, complexity, and time to the printing process compared to the printers with additional media flippers. 
   Furthermore, the user is presented front access to stapled/offset media output without the need to orient FOFAP  40  sideways. Access to primary output bin  402  is also not diminished with the use of folding offset output tray  405 . Moreover, because neither folding offset output tray  405  nor primary output bin  402  are bound on the output end by any mechanism, the height or depth of FOFAP  40  does not require significant increase to handle the larger sized paper stock, such as legal, A4, and the like. 
     FIG. 5A  is a diagram detailing diverting system  50  of FOFAP  40 , as shown in  FIG. 4 . Diverting mechanism  50  is activated when a staple/offset feature is selected. Print media exits fuser  401  and enters existing media flipper  403 . The print media begins exiting FOFAP  40  ( FIG. 4 ) until its trailing edge leaves fuser  401 . Once the print media clears fuser  401 , media flipper  403  reverses direction drawing the media back into FOFAP  40  ( FIG. 4 ) into duplex printing path  502 . However, when the stapler/offset feature is selected diverter  503  is in a closed position re-directing the print media into staple/stacker path  501  into stapler/stacker  404 . 
     FIG. 5B  is a diagram detailing open diverting system  51  of FOFAP  40 , as shown in  FIG. 4 . When normal or duplex printing is selected by the user, diverting system  51  remains in an open position. After passing through fuser  401 , if duplex operation is selected, the print media is reversed in media flipper  403  and directed down duplex printing path  502 . The print media does not get re-directed into stapler/stacker  403  through stapler/stacker path  501  because diverter  503  remains in its open position. 
     FIG. 6A  is a diagram detailing an alternative embodiment of diverting system  60  for FOFAP  40 , as shown in  FIG. 4 . Diverting mechanism  60  is activated when a staple/offset feature is selected. Print media exits fuser  401  and enters existing media flipper  403 . The print media begins exiting FOFAP  40  ( FIG. 4 ) until its trailing edge leaves fuser  401 . Once the print media clears fuser  401 , media flipper  403  reverses direction drawing the media back into FOFAP  40  ( FIG. 4 ) into duplex printing path  502 . However, when the stapler/offset feature is selected gate  600  is in a closed position allowing the print media into staple/stacker path  501  into stapler/stacker  404 . 
     FIG. 6B  is a diagram detailing open diverting system  61  of FOFAP  40 , as shown in  FIG. 4 . When normal or duplex printing is selected by the user, diverting system  61  remains in an open position. After passing through fuser  401 , if duplex operation is selected, the print media is reversed in media flipper  403  and directed down duplex printing path  502 . When duplex printing is selected, gate  600  and diverter  601  are moved into a diverting position such that print media does not get re-directed into stapler/stacker  404  through stapler/stacker path  501  because diverter  601  blocks entry to stapler/stacker  404 . 
   It should be noted that, while  FIGS. 5 and 6  detail two alternative embodiments of a diverting system, various embodiments of the present invention may be configured with other implementations for diverting the printed media from the duplex path into the stapler/stacker assembly. 
   Also, it should be noted that, while  FIG. 4  is shown with a monochrome printer, alternative embodiments of the present invention may be configured on color printers.  FIG. 7  is a side view of another embodiment of FOFAP  70  configured with front-mounted color print mechanisms  702 – 705 , and front-mounted fusing system  701 . The diverting system of  FIG. 7  operates similarly to that shown in  FIG. 4  except for the additional ones of color print mechanisms  702 – 705 . Print media on main path  700  and duplex path  706  will pass through color print mechanisms  702 – 705  to reach front-mounted fusing system  701 . 
   Although the present invention and its advantages have been described in detail, it should be understood that various changes, substitutions and alterations can be made herein without departing from the spirit and scope of the invention as defined by the appended claims. Moreover, the scope of the present application is not intended to be limited to the particular embodiments of the process, machine, manufacture, composition of matter, means, methods and steps described in the specification. As one of ordinary skill in the art will readily appreciate from the disclosure of the present invention, processes, machines, manufacture, compositions of matter, means, methods, or steps, presently existing or later to be developed that perform substantially the same function or achieve substantially the same result as the corresponding embodiments described herein may be utilized according to the present invention. Accordingly, the appended claims are intended to include within their scope such processes, machines, manufacture, compositions of matter, means, methods, or steps.

Technology Category: 3