Patent Application
20120086760
This disclosure relates generally to phase change ink printers, and in particular to solid ink loaders for use in such printers.
Phase change ink imaging products encompass a wide variety of imaging devices, such as ink jet printers, facsimile machines, copiers, and the like, that are configured to utilize phase change ink to form images on recording media. Some of these devices use phase change ink in a solid form, referred to as solid ink sticks. Imaging devices that utilize solid ink sticks are typically provided with feed channels. Ink sticks are inserted into the feed channels through insertion openings and then urged by one or more drive members, gravity, or a combination thereof in a feed direction toward melting devices located at one end (i.e., the melt ends) of the channels where the ink sticks are melted to a liquid ink suitable for jetting onto recording media.
Each feed channel has an insertion area or region where ink sticks are received after passing through the corresponding insertion opening. To enable insertion of ink sticks into the feed channels, drive members, such as push blocks, are retracted to a rearward position beyond the insertion regions of the channels to provide clearance for ink sticks to be inserted into the insertion regions of the feed channels in front of the push blocks. After ink stick insertion has been completed, the push blocks are moved from the retracted position to apply an urging force to the trailing end of the last ink stick inserted into the channels. If there is space in front of the last ink stick, the urging force causes the ink stick to move forward in the channel until the ink stick abuts the trailing end of the previously inserted ink stick or moves forward until the ink stick impinges on the melting device located at the melt end of the channel if no other ink sticks are in the channel.
If the column of ink in a channel extends far enough from the melt end of the channel toward the insertion region, the next ink stick inserted into the channel may still protrude into the insertion region of the channel after being abutted against the trailing end of the column, preventing ink sticks from being inserted into the channel, at least temporarily. The position of the insertion opening relative to the melt end of a channel therefore controls the number of ink sticks capable of being loaded into the channel at any given time in these systems. Consequently, the insertion openings of the channels are typically located as far away from the melt ends of the channels as possible to maximize the number of ink sticks capable of being loaded into the channels.
In some imaging device configurations, however, the lengths of the feed channels may be limited because the area most distant from the melt ends of the channels may be inaccessible for ink stick insertion. Consequently, the insertion openings for the feed channels of the ink loader in these devices have to be located at a location that shortens the potential length of the feed channel. Thus, the number of ink sticks (and the amount of ink) that may otherwise be loaded into the channels is decreased. A similar situation exists if there is an opportunity to increase channel length and thus ink capacity.
In accordance with the present disclosure, an ink stick retraction system has been developed for use in the ink loader of a phase change ink imaging device that enables feed channels to incorporate ink stick insertion openings that are positioned at intermediate locations of the feed channel by using an ink stick retraction system. In one embodiment, a solid ink loading system for a phase change ink imaging device includes an ink loader having a first end, a second end, and at least one feed channel extending between the first and the second end. The at least one feed channel includes an insertion region intermediate the first and the second end where ink sticks enter the at least one feed channel. The at least one feed channel is configured to guide ink sticks in a feed direction from the insertion region toward the second end. An ink stick retractor is configured for movement between a forward position and a rearward position substantially parallel to at least a portion of the at least one feed channel. The forward position is closer to the second end of the feed channel than the first position. The ink stick retractor is configured to selectively move ink sticks in the at least one feed channel in a retraction direction toward the first end.
A solid ink loading system for a phase change ink imaging device includes an ink loader having a first end, a second end, and at least one feed channel extending between the first and the second end. The at least one feed channel includes an insertion region intermediate the first and the second end where ink sticks enter the at least one feed channel. The at least one feed channel is configured to guide ink sticks in a feed direction from the insertion region toward the second end. The solid ink loading system includes an ink feed system configured to move ink sticks in the feed direction from the insertion region toward the second end; and an ink stick retractor configured to move ink sticks in the retraction direction from the insertion region toward the first end.
a-6c depict an alternative embodiment of an ink stick retraction system for use in the ink loader of the imaging device of
a-7d depict another alternative embodiment of an ink stick retraction system for use in the ink loader of the imaging device of
For a general understanding of the present embodiments, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate like elements.
Ink sticks 14 are inserted into an insertion region 30 of the feed channels through insertion openings 16. The insertion region of a feed channel refers to the portion of the guide path of the feed channel where an ink stick comes to rest upon entry into the channel. In the embodiment of
After an ink stick 14 has been inserted into the channel, the ink stick is moved in a feed direction F toward the melting assembly 20 at the end of the channel 18 by a mechanized delivery system and/or by gravity until the ink stick 14 abuts against the trailing end of a previously inserted ink stick or impinges on a melting device, such as a melt plate, at the melting assembly 20 if no other ink sticks are in the channel 18. In the embodiment of
The push block 22 is retracted in a direction opposite the feed direction F (i.e., a retraction direction R) toward the opposite end of the channel 18 from the melt assembly 20 to enable ink sticks to be inserted into the insertion region 30 of the channel in front of the push block 22. As explained below, the feed channels 18 of the ink loader 12 are provided with an ink stick retraction system 200 configured to move one or more ink sticks 14 located at the trailing end of the column of ink in each channel in the retraction direction R to provide a clear space in the feed channel for the insertion region 30. The ability to retract ink sticks enables the insertion regions of the channels to be located at an intermediate location of the feed channel without decreasing or limiting the number of ink sticks that may be loaded into the channel.
The feed channel 18 guides the column of ink sticks 14 toward the melting assembly 20 at one end of the channel 18 where the sticks are heated to a phase change ink melting temperature to melt the solid ink to form a molten liquid ink, also referred to as melted ink. Any suitable melting temperature may be used depending on the phase change ink formulation. In one embodiment, the phase change ink melting temperature is approximately 80° C. to 130° C. The melted ink is received in a reservoir 24 configured to maintain a quantity of the melted ink in molten form for delivery to printing system 26 of the device 10.
The printing system 26 includes at least one printhead 28 having inkjets arranged to eject drops of melted ink onto an ink receiving surface. Any suitable number of printheads 28 may be used. Each printhead may be configured with reservoir 24 or may be in fluid communication with reservoir 24. The device 10 of
The imaging device 10 includes a media supply and handling system 48 that is configured to transport recording media along a media path 50 defined in the device 10 that guides media through the nip 44, where the ink is transferred from the intermediate surface 32 to the recording media 52. The media supply and handling system 48 includes at least one media source 58, such as supply tray 58 for storing and supplying recording media of different types and sizes for the device 10. The media supply and handling system includes suitable mechanisms, such as rollers 60, which may be driven or idle rollers, as well as baffles, deflectors, and the like, for transporting media along the media path 50.
Media conditioning devices may be positioned along the media path 50 for controlling and regulating the temperature of the recording media so that the media arrives at the nip 44 at a suitable temperature to receive the ink from the intermediate surface 32. For example, in the embodiment of
Operation and control of the various subsystems, components and functions of the imaging device 10 are performed with the aid of a control system 68. The control system 68 is operably coupled to receive and manage image data from one or more image sources 72, such as a scanner system or a work station connection, and to generate control signals that correspond to the image data. These signals cause the components and systems to perform the various procedures and operations for the imaging device 10. The control system 68 includes a controller 70, electronic storage or memory 74, and a user interface (UI) 78. The controller 70 comprises a processing device, such as a central processing unit (CPU), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA) device, or microcontroller, configured to execute instructions stored in the memory 74. Any suitable type of memory or electronic storage may be used. For example, the memory 74 may be a non-volatile memory, such as read only memory (ROM), or a programmable non-volatile memory, such as EEPROM or flash memory.
User interface (UI) 78 comprises a suitable input/output device located on the imaging device 10 that enables operator interaction with the control system 68. For example, UI 78 may include a keypad, buttons, or other similar types of manual actuators (not shown), and a display (not shown). The controller 70 is operably coupled to user interface 78 to receive signals indicative of selections and other information input to the user interface 78 by a user or operator of the device. Controller 70 is operably coupled to the user interface 78 to display information to a user or operator including selectable options, machine status, consumable status, and the like. The controller 70 may also be coupled to a communication link 84, such as a computer network, for receiving image data and user interaction data from remote locations.
The controller 70 is operably coupled to the various systems and components of the device 10, such as the ink handling system 12, printing system 26, media handing system 48, release agent application assembly 38, media conditioning devices, and other devices and mechanisms of the imaging device 10, and is configured to generate control signals that are output to these systems and devices in accordance with the print data and instructions stored in memory 74. The control signals, for example, control the operating speeds, power levels, timing, actuation, and other parameters, of the system components to cause the imaging device 10 to operate in various states, modes, or levels of operation, referred to collectively herein as operating modes.
As depicted in
Ink sticks, such as ink stick 14, may include a number of surface features that aid in the correct loading, guidance, feed control and support of the ink stick when used. As used herein, the term “surface features” and “features” used in relation to and ink sticks refers to topological contours, such as protrusions, recesses, grooves, and the like, that are sized, shaped, and/or otherwise configured to interact in some manner with one or more elements, devices, and members of an ink loader, or feed channel, such as key elements, guides, supports, sensors, etc. For example, the ink stick 14 includes insertion key feature 174 (
An ink stick may also include feed control and guidance features for interacting with various structures provided in the feed channel. For example, ink stick 14 includes a feed key groove 180 formed in the bottom surface 160 extending from the leading end surface 156 to the trailing end surface 154. The feed key groove 180 is configured to straddle a feed key (not shown) that extends from the feed channel. In alternative embodiments, the ink stick 14 may be provided with any suitable type of feed key feature for interacting in any manner with whatever type of keying, guidance or support members are provided in a feed channel. In addition, the ink stick 14 includes guide feature 184 near the bottom of side surface 168 and guide feature 186 near the top of side surface 158 for interacting with complementary structures in the feed channel to facilitate alignment of ink sticks in the channel and to limit contact between ink sticks and the feed channel structural elements, such as ribs, supports and other potentially restrictive surfaces. The typical ink loader in a desk top printer or MFP has generally been configured with linear feed channels. Various imaging products, including those of larger size, may have feed channels that are fully or partially non linear or any shape suited to the needs and available space in the product.
An ink stick may also include nesting features to facilitate alignment and feed guidance of the ink sticks in the feed channels. As depicted in
In addition to or as an alternative to the insertion, feed guidance, and nesting features, ink sticks may be provided with sensor features for conveying ink stick data to the print controller of the solid ink printer. The ink stick data encoded onto an ink stick may include identification information, such as color, formulation, and intended printer model, as well as printing information, such as printer settings or preferences for use with the ink stick. Sensor features comprise surface formations on the ink stick body that are configured to interact with sensors positioned at one or more locations in the insertion region and/or other portions of feed channels to convey ink stick data to the print controller of a solid ink printer.
Sensor features may have any suitable configuration that permits reliable sensor interaction, such as protrusions, recesses, reflective features, non-reflective features, and the like, depending on the type of sensor used. In the embodiment of
Ink stick data may be encoded into an ink stick by assigning data to the sensor feature 192. To extract the data from the sensor feature 192, the feed channel 18 is provided with a sensor system (not shown) capable of sensing, detecting, or being actuated by the recesses 194 of the sensor feature 192. The sensor feature 192 actuates the sensors of the sensor system causing the sensor system to output signals to the printer controller 70 indicative of the data assigned to the sensor feature 192. The controller 70 may then use the data to influence operations of the printer. For example, in one embodiment, once the ink stick data has been identified, the controller 70 may determine whether or not the ink stick is compatible with the printer and enable or disable operations accordingly.
Each feed channel includes a feed mechanism for urging ink sticks that have been inserted into the channels toward the melting device 104 located at the melt end 100 of the channel. In the embodiment of
In the embodiment of
When the yoke 118 is in the forward position J, the constant force spring 114 pulls the push block 22 toward the melt end 100 of the channel to a location proximate the yoke 118. If ink sticks are positioned in the feed channel 18 in front of the push block 22, the pulling force of spring 114 on the push block 22 causes the push block 22 to move into contact with the trailing end of the ink sticks in the channel and urge the ink sticks toward the melt end 100 of the channel 18. The spring 114 is coupled to the hub of the push block 22 in a manner that enables the spring body to extend between the yoke 118 and the push block 22 without interfering with ink stick movement in the feed channel. For example, as depicted in
To enable the insertion of ink sticks into the channel 18, the push block 22 is moved toward the insertion end 98 of the feed channel to a retracted position located beyond the insertion region 30 of the channel to enable ink sticks to be inserted into the feed channel in front of the push block (relative to the feed direction F). To move the push block 22 to the retracted position, the yoke 118 is moved from the forward position J to the rearward position K. When the yoke 118 is in its rearward position, the spring 114 coils within the push block 22 enabling the push block 22 to be moved by the yoke in the retraction direction R to its retracted position in the feed channel.
The yoke 118 is coupled to an actuation system 124 that is configured to move the yoke 118 between the forward and rearward positions J, K to enable ink loading operations. Any suitable type of actuation system may be used including manually operated actuation, electro-mechanical actuation, or a combination thereof. For example, in one embodiment, the yoke is coupled by a suitable linkage to a manually operated access cover that controls access to the insertion openings 16 of the ink loader. When the access cover is opened, the linkage 122 retracts the yoke 118 to its rearward position K which in turn causes the push block 22 to be retracted toward the first end 98 of the feed channel. When the access cover is closed, the linkage moves the yoke 118 to its forward position J thereby moving the push block 22 forward in the channel 18 and into the urging position. As an alternative to manually controlling yoke 118 position, some devices may include a motorized actuation system 124 configured to control the position of the yoke 118 to enable ink loading operations. A motorized actuation system 124 may be activated in any suitable manner such as by input received from the user interface 78 and/or by control signals received from the device controller 70. In embodiments, the controller 70 may be configured to control the actuation system 124 to enable ink loading based on user input as well as other factors, such as device operating state.
During ink loading operations, if a previously loaded ink stick is located even partially in the insertion region 30 of the channel 18, the insertion of an ink stick into the channel may be prevented. For example, depending on the position of the insertion region 30 in the channel, when multiple ink sticks are loaded into a channel and abutted against each other to form a column of ink, the column of ink may extend from the melt end 100 of the channel a distance such that the trailing end of the column protrudes into the insertion region 30 of the channel. To enable ink stick insertion in circumstances such as this, the feed channel 18 may be equipped with an ink stick retraction system 200 in accordance with one embodiment of the present disclosure. The ink stick retraction system 200 is configured to transport or move one or more ink sticks in the retraction direction R along the feed channel to a position between the first end 98 of the feed channel and the insertion region 30 in order to clear the insertion region 30 of the channel 18 for ink loading. This function enables numerous ink loader configurations, including insertion openings intermediate the ends of the feed channel and ink insertion “drawers” that can be pulled out from the main ink loader body to replenish ink. To enable clearance of the insertion region 30 by the retraction system 200, the feed channel 18 includes a staging area or section 218 that extends between first end 98 of the channel and the trailing edge 210 of the insertion region that is sized to accommodate the desired number of retracted ink sticks and any push block or similar feed associated components.
As depicted in
To facilitate reliable interaction between the ink stick engaging portion 208 of the retractor 204 and an ink stick 14 during retraction, ink sticks 14 may be provided with a motion control inset 220. As depicted in
The ink stick retractor 204 is coupled to a drive system that enables the retractor 204 to be controllably moved between the forward and rearward positions. In the embodiment of
The main body 206 positions the ink stick engaging portion 208 of the retractor 204 a suitable distance in front of the push block 22 to enable the ink stick engaging portion 208 to extend into the feed channel in front of at least a portion of an ink stick 14 located in front of the push block. The distance that the main body 206 extends from the push block 22 is selected based on the size and number of ink sticks that is required to be retracted in order to clear the insertion area 30 for a given feed channel configuration. Depending on the position of the insertion region 30 of the channel 18 relative to the ends 98, 100 of the channel, one or multiple ink sticks may have to be retracted in order to clear the insertion area.
The main body 206 of the retractor may be connected to the push block in a manner that enables the main body 206 and the ink stick engaging portion thereof to move between a lowered position in which the ink stick engaging portion is located outside of the feed path of the feed channel and an elevated position in which the ink stick engaging portion 208 is located in the feed path of the feed channel. In the embodiment of
In other embodiments, the retractor 204 may be slidably coupled to the push block 22 so that full forward motion toward the melt end of the channel 18 is enabled. In the exemplary embodiment shown in
Referring now to
The retractor 304 is also configured to interact with a cam 310 that is configured to control the movement of the retractor 304 between the clearance and engaged positions based on the direction of movement and/or position of the yoke 118 relative to the feed channel. A spring 314, or other suitable biasing structure, is positioned between the retractor 304 and the yoke to bias the retractor 304 toward the clearance position and into an intermediate, or neutral, position to facilitate engagement with the cam 310.
As depicted in
a-6d depict one possible embodiment of a yoke mounted retractor. In alternative embodiments, a number of other suitable cam or cam track arrangements may be utilized. In addition, the retractor 304 may have a number of other configurations that enable the retractor to move ink sticks in the retraction direction with the movement of the yoke. The retractor 304 may comprise a flexure or cantilever or may be pivotally mounted to the yoke 118 so that the ink stick engaging portion 308 is located above the top surface of the ink sticks during movement of the yoke 118 in the feed direction F and is moved downwardly into the ink stick path of the feed channel 18 by a suitable feature, such as a cam or cam track interaction, to catch the top of an ink stick (not shown in
a-7c depict an embodiment of an ink stick retraction system 400 that is configured for movement independent of the feed mechanisms of the ink loader 12. The system 400 includes a retractor 404 supported by a retractor drive system 410 that is configured to translate the retractor 404 between a forward position (
In the embodiment of
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. Various presently unforeseen or unanticipated alternatives, modifications, variations, or improvements therein may be subsequently made by those of ordinary skill in the art, which are also intended to be encompassed by the following claims.
