Patent Application
20090162113
Currently, in the field of printing machines that use magnetic ink character recognition toner (MICR), MICR is only used on an infrequent basis to process financial documents that require the special characteristics of MICR toner. This is because the toner run costs for MICR is significantly higher than the run costs for conventional toner. Consequently, MICR machines generally remain idle for a considerable amount of time. The present embodiments relate to a printing system that would eliminate the need for a separate machine dedicated to only the one task of printing documents with MICR toner.
This disclosure is generally directed to a printing system that incorporates distinct printing processes into a cohesive printing unit, such that efficiency and lower run time costs are achieved. The present disclosure incorporates a MICR printing system with a high run volume monochrome printing system. The system could also be configured to use another special toner other than MICR, or two or more combined special toners. The printing system may include an intermediate transfer belt configured for transferring an image to a print media in one rotation, a first image developing component wherein a first photoreceptor drum is configured for applying a first toner, in a first revolution of the first photoreceptor drum, to the intermediate transfer belt, a second image developing component wherein a second photoreceptor drum is configured for applying a second toner, in a first revolution of the second photoreceptor drum, to the intermediate transfer belt, a first intermediate transfer belt pathway that connects the first image developing component and the second image developing component, and a second intermediate transfer belt pathway that bypasses the second image developing component. In order to transfer a combined image, including the first toner from the first photoreceptor drum and the second toner from the second photoreceptor drum, to print media the intermediate transfer belt may be configured to transfer the combined image to an image transferring means during a first rotation of the intermediate transfer belt.
The various embodiments may include use of different types of a first and second toner. A preferred embodiment includes a varied combination of monochrome toner or a magnetic ink character recognition toner. For example, in one embodiment, the first toner may be monochrome toner and the second toner may be magnetic ink character recognition toner. In a second embodiment, the first toner may be magnetic ink character recognition toner and the second toner may be monochrome toner.
In another embodiment, the printing system may include an intermediate transfer belt configured for transferring an image to print media in two rotations, a first image developing component wherein a first photoreceptor drum is configured for applying a first toner to the intermediate transfer belt, a second image developing component wherein a second photoreceptor drum is configured for applying a second toner to the intermediate transfer belt, a third image developing component wherein the first photoreceptor drum is configured for applying a third toner to the intermediate transfer belt and a fourth image developing component wherein the second photoreceptor drum is configured for applying a fourth toner to the intermediate transfer belt. This embodiment may require two rotations of the intermediate transfer belt and two revolutions of the first and second photoreceptor drums in order to transfer a combined image, including images formed from the first, second, third and fourth toners, to print media.
The printing system may also include an image transferring means that transfers the image on the intermediate transfer belt to the print media, which may include printing paper, financial documents such as checks, and the like. Furthermore, in order to accomplish a high quality transfer to print media the printing system may also include a fuser means that fuses the image to the print media. The fuser means could receive the print media from a pathway that connects the image transferring means to the fuser means.
In an exemplary embodiment, the printing system incorporates a method of printing including creating a combined image by transferring a first toner image to the intermediate transfer belt from the first photoreceptor drum, wherein a first image developing component is configured for applying a first toner, in a first revolution of the first photoreceptor drum, to the intermediate transfer belt. The method of printing further includes transferring a second toner image to the intermediate transfer belt from the second photoreceptor drum, wherein a second image developing component is configured for applying a second toner, in a first revolution of the second photoreceptor drum, to the intermediate transfer belt. Transferring the first and second toner images to the intermediate transfer belt creates a combined image, the combined image is then transferred to print media in a first rotation of the intermediate transfer belt.
This disclosure is not limited to the particular embodiments described herein, and some components and processes may be varied by one of ordinary skill in the art, based on this disclosure. The terminology used herein is for the purpose of describing particular embodiments, and is not intended to be limiting. Aspects of the exemplary embodiments, as disclosed, relate to a printing system that is capable of both monochrome and MICR printing and to a method of printing the same. Aspects of the exemplary embodiments, as disclosed, also relate to a printing system that is capable of producing images formed from various combinations of toners, including a combination of two, three or four different toners, and to a method of printing the same.
The printing system 10, as shown in
The printing system 10 incorporates a rastor output scanning system 50, which uses a laser or like device that serves as a photon source 60 to disperse a sheet of photons across a surface of the photoreceptor drums 20 and/or 30. The printing system 10 is configured in such a way that both photoreceptor drums 20 and 30 can be jointly used or only one photoreceptor drum is used for certain printing tasks. Moreover, the rastor output scanning system 50 is capable of creating a first toner image using photoreceptor drum 30 and a second toner image, not related to the first image, using photoreceptor drum 20.
In one embodiment of this disclosure, the applicable photoreceptor drums 20 and/or 30 are first charged to a uniform state by application of an electrostatic charge. Charge applying unit 54 applies an electrostatic charge to exterior surface 80 of photoreceptor drum 20. Charge applying unit 56 applies an electrostatic charge to exterior surface 90 of photoreceptor drum 30. After which, a stream of photons 70, by the photon source 60, is applied to an exterior surface 80 and/or 90 of the respective photoreceptor drums 20 and 30. The photon source 60 can be pulsed on and off such as to create a pattern on the surface of the photoreceptor drums 20 and/or 30. The stream of photons 70 work to discharge the electrostatic energy on the exterior surfaces 80 and/or 90 of photoreceptor drums 20 and/or 30. This results in distinct areas on the exterior surfaces 80 and/or 90 having a charged state and distinct areas on the exterior surfaces 80 and/or 90 not having a charged state. The pulsation of the photon source 60 and rotation of the photoreceptor drums 20 and/or 30 results in the creation of an image code on the exterior surfaces 80 and/or 90 of the photoreceptor drums 20 and/or 30.
While the photon source 60 is applying a stream of photons 70 to the exterior surfaces 80 and/or 90, the photoreceptor drums 20 and/or 30 are also rotating. The drums 20 and 30 rotate around developer housings 100 and 110, respectively. The developer housings 100 and 110 are responsible for applying toner to the charged surfaces of the exterior surfaces 80 and 90, respectively. In the first embodiment, as shown in
In another embodiment, developer housing 100, associated with photoreceptor drum 20, is adapted to apply magnetic ink character recognition toner, also known as MICR toner, to exterior surface 80. Therefore, developer housing 110, associated with photoreceptor drum 30, may be adapted to apply monochrome toner, also known as K toner, to exterior surface 90. In further embodiments, developer housings, 100 and 110, associated with photoreceptor drums 20 and 30, respectively, may be adapted so that both apply K toner or MICR toner.
The exterior surfaces 80 and 90 of photoreceptor drums 20 and 30, respectively, are capable of transferring toner onto intermediate transfer belt 40. The intermediate transfer belt 40 extends between the two photoreceptor drums 20 and 30. The intermediate transfer belt 40 has an intermediate transfer belt moving means 120, which enables it to accept a toner image formed by toner transferred from the exterior surfaces 80 and/or 90 and deliver a final combined image to an image transferring means 130.
In one embodiment, as shown in
The intermediate transfer belt 40 and exterior surfaces 80 and 90 use a toner image transferring means 145 to transfer a toner image from the exterior surfaces 80 and 90 to the intermediate transfer belt 40. One means by which to accomplish the transfer is to apply electrostatic force to the intermediate transfer belt 40. The electrostatic force acts to place pressure on the intermediate transfer belt 40 such that the intermediate transfer belt 40 comes into direct contact with exterior surfaces 80 and 90. An example of such an embodiment is to have an electrostatic force applying means below the intermediate transfer belt 40 at the location where the intermediate transfer belt 40 comes into direct contact with exterior surfaces 80 and 90. As shown in
Transfer rollers 140 and 150 act to apply electrostatic force at contact regions 160 and 170, respectively. Specifically, contact region 160 is the area where intermediate transfer belt 40 comes into direct contact with exterior surface 80 of photoreceptor drum 20. At this contact region 160, a toner image formed from toner is transferred from the exterior surface 80 to the intermediate transfer belt 40. The transferring of the image is aided by the toner image transferring means, which in the embodiment shown in
Contact region 170 is the area where intermediate transfer belt 40 comes into direct contact with exterior surface 90 of photoreceptor drum 30. At this contact region 170, a toner image formed from toner is transferred from the exterior surface 90 to the intermediate transfer belt 40. The transferring of the image is aided by the toner image transferring means, which in the embodiment shown in
After the toner image, in the form of toner, has been transferred to the intermediate transfer belt 40, exterior surfaces 80 and 90 are cleaned such that residual toner that was not transferred to the intermediate transfer belt 40 is removed. This is accomplished by an exterior surface cleaning means. For example, cleaning station that contacts, directly or indirectly, the exterior surface of a photoreceptor drum can act as an exterior surface cleaning means.
After the exterior surfaces 80 and 90 have been cleaned, by cleaning stations 180 and 190 respectively, a new charge can be applied to each surface by charge applying units 54 and 56 such that the printing process can begin again. Specifically, after exterior surface 80 has been cleaned by cleaning station 180, exterior surface 80 is ready to receive a new charge such that a new image can be formed on the exterior surface. Therefore, at this point the raster output signal will start the process for creating a new latent image, to be formed from toner, on the exterior surfaces 80 and/or 90. Consequently, the photoreceptor drums 20 and 30, together with developer housings 100 and 110, are able to accomplish transfer of toner images from the exterior surfaces 80 and 90 to the intermediate transfer belt 40. Transfer of a first image, formed of toner, from the exterior surface 90 to the intermediate transfer belt 40 occurs within a first revolution of the photoreceptor drum 30. Furthermore, transfer of a second image, formed of toner, from the exterior surface 80 to the intermediate transfer belt 40 occurs within a first revolution of the photoreceptor drum 20. Moreover, the combined image, which includes the first toner image and the second toner image, is transferred to the image transferring means 130 during a first rotation of the intermediate transfer belt 40. Transfer of the combined image from the intermediate transfer belt 40 to a print media occurs at contact area 135. Specially, the printing system shown in
In a single pass architecture, a first revolution of a first photoreceptor drum would be required to transfer a first toner to an intermediate transfer belt. For example, as shown in
In reference to
Further referencing
After the intermediate transfer belt 40 progresses beyond the photoreceptor drums, a final combined image is ready to be transferred to a print media. The printing system uses an image transferring means 130 to transfer the combined image from the intermediate transfer belt 40 to a print media. In one embodiment, as shown in
Once the final combined image has been transferred to a print media, the print media can also pass through a fuser assembly 210. The fuser assembly fuses the combined image transferred from the intermediate transfer belt 40 to the print media to create a permanent image. Sheets fused with the final toner image can be assembled to an output destination (not shown) such as a finisher. The print media source, printing system 10 and output destinations can all be interconnected by a print media conveyor system (not shown).
After the combined image has been transferred from the intermediate transfer belt 40 to print media, the intermediate transfer belt can be cleaned to remove residual toner. The cleaning process can utilize the intermediate transfer belt moving means 120 in combination with a cleaning station. For example, cleaning station 215, as shown in
The printing system could also be configured with a two-pass architecture, which would require a first and second revolution of the photoreceptor drums and two rotations of the intermediate transfer belt to create a final combined image. Specifically, a second embodiment with this type of two pass architecture would require two separate developer housings to be associated with a single photoreceptor drum. As shown in
In a two pass architecture, by way of the two-pass intermediate transfer belt 280, in a first revolution photoreceptor drum 220 may apply, using the same types of mechanisms and methods as discussed with the single-pass embodiment, to the two-pass intermediate transfer belt 280 a first toner associated with a first developer housing 230. In a second revolution, photoreceptor drum 220 may apply a second toner associated with a second developer housing 240. In another embodiment, the first toner could be associated with a first developer housing 240 and the second toner could be associated with a second developer housing 230. Furthermore, in a first revolution, photoreceptor drum 250 may apply a first toner associated with a third developer housing 260. In second revolution, photoreceptor drum 250 would apply a second toner associated with a fourth developer housing 270. In another embodiment, the first toner would be associated with a third developer housing 270 and the second toner with a fourth developer housing 260.
As shown in
During the first rotation of the intermediate transfer belt 280, two toner images can be transferred to the belt. Transferring of the third and four toner images requires a second pass, i.e. second rotation, of the intermediate transfer belt 280. Therefore, by way of intermediate transfer belt moving means 290 the intermediate transfer belt 280 can make a second rotation. During the second rotation, photoreceptor drum 250 can transfer a third toner image and photoreceptor drum 220 can transfer a fourth toner image. As discussed above, either developer housing 260 or 270 can supply the toner for the third toner image and either developer housing 230 or 240 can supply the toner for the fourth toner image. In an embodiment, if developer housing 260 supplies the toner for the first toner image, then developer housing 270 supplies the toner for the third toner image. In the alternative, if developer housing 270 supplies the toner for the first toner image, then developer housing 260 supplies the toner for the third toner image. Furthermore, if developer housing 230 supplies the toner for the second toner image, then developer housing 240 supplies the toner for the fourth toner image. In the alternative, if developer housing 240 supplies the toner for the second toner image, then developer housing 230 supplies the toner for the fourth toner image. Therefore, each developer housing, 230, 240, 260 and 270, may supply a different type of toner for at least one toner image when then the system is not set in a bypass mode.
In reference to the two-pass architecture, when the system is set in a bypass mode, the photoreceptor drum can be bypassed in both rotations of the intermediate transfer belt 280. The printing system can also be configured such that the photoreceptor drum is only bypassed in a first or second rotation of the intermediate transfer belt 280.
Another embodiment incorporates the essential features of a two-pass architecture and a single-pass architecture into one printing system and this embodiment would use the same mechanisms and methods of printing as previously discussed for the first and second embodiments. For example, a first photoreceptor drum may be configured like a two-pass system and a second photoreceptor drum may be configured like a single pass system. Such that in a first revolution the first photoreceptor drum would apply a first toner to the intermediate transfer belt in a first rotation of the intermediate transfer belt and in a second revolution the first photoreceptor drum would apply a second toner to the intermediate transfer belt in a second rotation of the intermediate transfer belt. A second photoreceptor drum could apply a first toner to the intermediate transfer belt in a single revolution of the photoreceptor drum in either the first or second rotation of the intermediate transfer belt. Therefore, one photoreceptor drum could transfer a toner image in one rotation of the intermediate transfer belt and the other photoreceptor drum would require two rotations of the intermediate transfer belt. Moreover, this system would require an intermediate transfer belt moving means that enables two rotations of the intermediate transfer belt. However, during the first or second rotation the intermediate transfer belt could automatically bypass one of the photoreceptor drums. Furthermore, according to this embodiment, one photoreceptor drum could include two separate developer housing units, such that each would be capable of supplying a different type of toner. The other photoreceptor drum, which can be automatically bypassed in either a first or second rotation of the intermediate transfer belt, would include one developer housing unit that is capable of supplying one type toner. Preferably, each developer housing unit would supply a different type of toner to the printing system.
In an embodiment including the two photoreceptor drums configured for single-pass architecture, a method of printing, as shown in
In an embodiment including two photoreceptor drums in a two-pass architecture, a method of printing, as shown in
In an embodiment including one photoreceptor drum in a single-pass architecture and one photoreceptor drum in a two-pass architecture, a method of printing may include two photoreceptor drums that are interconnected by an intermediate transfer belt. This method of printing may include a first photoreceptor drum, wherein a first image developing component may be configured for applying a first toner in a first revolution of the first photoreceptor drum; and a second photoreceptor drum, wherein a second image developing component may be configured for applying a second toner in a first revolution of the second photoreceptor drum. The first and second toners may be transferred to the intermediate transfer belt during a first rotation of the intermediate transfer belt. Next, a third image may be transferred to the intermediate transfer belt, wherein a third image developing component may be configured for applying a third toner in a second revolution of either the first or second photoreceptor drum. The combined image, which includes the first, second and third toner images, may be formed on the intermediate transfer belt and may then be transferred to a print media. This method of printing may also be configured such that a first toner is transferred during a first rotation of the intermediate transfer belt and the second and third toners are transferred during a second rotation of the intermediate transfer belt.
The printing system of any of the embodiments discussed above, may also have a bypass mode, such that one photoreceptor drum or developer housing could be bypassed. The bypass mode may enable the printing system to disengage one of the photoreceptor drums such that the intermediate transfer belt is taken out of contact with the photoreceptor drum. The photoreceptor drum can be disengaged from the intermediate transfer belt during a first and/or second rotation of the intermediate transfer belt.
It will be appreciated that variations of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, and are also intended to be encompassed by the following claims.
