This application claims priority under 35 U.S.C. § 119(a) to Application No. 20204779.1, filed in Europe on Oct. 29, 2020, the entire contents of which is hereby incorporated by reference into the present application.
The invention relates to a method of handling a sheet defect error in a duplex print process wherein media sheets are successively supplied along a feed path and are moved past a print engine where a first image is printed on a first side of each sheet in a first print pass, the sheets are then returned, via a duplex loop that contains a sheet flipping mechanism, to the feed path upstream of the print engine so that a second image can be printed on a second side of each sheet in a second print pass, the finished sheets being then discharged in a predetermined page sequence, and wherein, when a sheet defect is found in the first print pass of a sheet, the defective sheet is diverted into an eject path downstream of the print engine, and a print pass for an immediate successor of the defective sheet is skipped.
More particularly, the invention relates to a method of handling sheet defect errors in an ink jet printer. The print engine of an ink jet printer comprises an array of ink jet print heads that are arranged above a print surface that forms part of the feed path for the media sheets, so that ink droplets may be ejected onto a sheet passing through. In order to achieve a high print quality, the print heads should form only a narrow gap with the top surface of the media sheets on the print surface. Then, if a sheet has a defect that results in parts of the sheet projecting upwards from the print surface, e.g. due to waviness of the sheet or a fissure in the sheet, there is a risk that the print heads collide with the projecting part of the sheet or that at least the projecting part of the sheet comes in contact with the print head, which may cause damage not only to the sheet but also to the print heads. In particular, the fine nozzles of the print heads may become clogged with dust or partly-dried ink scratched from the surface of the sheet. Furthermore, this may result in the print engine or other parts of the printer becoming contaminated with ink or primer.
US 2018345693 A1 discloses an ink jet printer wherein a detector and a sheet ejector are provided for detecting and ejecting defective sheets upstream of the print engine.
In duplex printing, when a defective sheet has been ejected that carried already a first image on its first side, it is generally necessary to re-arrange the print order so as to preserve the page sequence of the finished sheets that are stacked on an output tray of the printer. Frequently, this requires that at least some of the semi-finished sheets in the duplex loop must be discarded even when these sheets have no defects.
In other ink jet printers, which have no sheet surface height scanner for detecting defective sheets, sheet defect errors such as a collision of parts of a sheet with the print heads may occur from time to time. In these printers, the defective sheets are ejected only downstream of the print engine when an error has actually occurred. However, it may then be necessary to start a print head recovery routine for restoring the proper function of the print heads, for example by wiping a nozzle face of the print head or by “spitting” liquid ink from the nozzles of the print head or printing recovery patterns in order to remove any contaminants from the nozzle orifices. In such printers, a waste of semi-finished sheets may occur even when the sheet defect error occurs in the first print pass of a sheet. The reason is that the recovery time that is needed for restoring the proper function of the print heads may be longer than the time interval between two successive media sheets, so that the immediate successor of the defective sheet, which will in general be a semi-finished sheet returning from the duplex loop, reaches the print engine already at a time before the print heads are again ready for printing. Consequently, this sheet and all subsequent semi-finished sheets returning from the duplex loop must be discarded in order to preserve the page order of the sheets. Thus, if the duplex loop contains a large number of sheets, a considerable amount of waste will be produced. In some ink jet printers, the capacity of the duplex loop may be as large as 36 sheets, for example.
It is therefore an object of the invention to provide a method for handling sheet defect errors with reduced production of waste.
In order to achieve this object, the method according to the invention is characterized in that the subsequent semi-finished sheets are recirculated in the duplex loop while the supply of fresh sheets into the feed path is interrupted, and duplex printing is resumed during or after recirculating the subsequent semi-finished sheets.
Thus, when a sheet defect error occurs in the first print pass of a sheet, the semi-finished sheet that is the immediate successor of the defective sheet and that cannot yet be finished by printing the second image, is not discarded but is recirculated in the duplex loop until it reaches the print engine again in the right orientation for receiving the second image on its second side. A number of subsequent semi-finished sheets will also be kept circulating in the duplex loop until printing is resumed with the sheet that was the immediate successor. This will assure that the page order of the printed sheets is not disrupted. Of course, as long as the sheets are recirculated in the duplex loop, the loop will not be cleared of finished sheets, and, consequently, the supply of fresh sheets into the duplex loop must be interrupted at least for a certain time in order to avoid an overflow of the duplex loop. A first fresh sheet may be supplied again at an appropriate timing for replacing the defective sheet that has been discarded.
The principle of the invention is also applicable in a case where a sheet defect error does not occur in the first print pass of a sheet but in the second print pass. The only difference is that in this case, since the immediate successor of the defective sheet will be a fresh sheet that does not yet carry any image, there is a choice whether to discard this sheet or to keep it. For reasons that will be explained below, there may be good reasons to discard the immediate successor and optionally also one or more semi-finished sheets following immediately thereafter. However, the bulk of the semi-finished sheets will be kept circulating in the duplex loop until they reach the print engine again in the correct orientation for being finished, so that duplex printing can be resumed. The first fresh sheets that will be printed on when duplex printing is resumed will in this case be the sheets that replace the sheets that have been discarded.
Thus, in another aspect, the invention also provides a method of handling a sheet defect error in a duplex print process wherein media sheets are successively supplied along a feed path and are moved past a print engine where a first image is printed on a first side of each sheet in a first print pass, the sheets are then returned, via a duplex loop that contains a sheet flipping mechanism, to the feed path upstream of the print engine so that a second image can be printed on a second side of each sheet in a second print pass, the finished sheets being then discharged in a predetermined page sequence, and wherein, when a sheet defect is found in the second print pass of a sheet, the defective sheet is diverted into an eject path downstream of the print engine, and a print pass for an immediate successor of the defective sheet is skipped, characterized in that a number of the subsequent semi-finished sheets are recirculated in the duplex loop while the supply of fresh sheets into the feed path is interrupted, and duplex printing is resumed with the recirculated sheets.
It is noted that the invention may also be advantageously applied in a duplex print process that is provided with a sheet surface height scanner, as it reduces waste in the case sheets returning from the duplex loop have deformed too much since the first print pass. For example, the sheet was originally (prior to the first print pass) not found defective, but due to for example the sheet becoming moist during the first print pass, or due to drying in the duplex loop, or due to transportation in the paper path, the sheet deforms and has become defective. Furthermore, an eject path for the defective sheet may be located upstream of the print engine to remove the sheet prior to it passing the print engine, as well as downstream of the print engine to remove the sheet after it has passed the print engine.
More specific optional features of the invention are indicated in the dependent claims.
Depending upon the design of the feed path, it may not be possible to stop the supply of fresh sheets immediately when a sheet defect error occurs. For example, the feed path will frequently comprise a portion that is located upstream of a switch where the duplex loop joins the feed path. If fresh sheets have been supplied already into that portion of the feed path, it may not be possible or not be desirable to stop these sheets. Instead, these sheets can be moved on past the print engine and may then be diverted into the eject path in order to prevent an overflow of the duplex loop.
If the recovery procedure for the print engine comprises for example a step of spitting ink out of the nozzles, then the fresh sheets that will be discarded may be utilized to catch the ink that is spit from the nozzles, so that the print surface is not contaminated with ink. Likewise, the fresh sheets to be discarded may be utilized to print recovery patterns on.
Similarly, if the sheet defect error occurs in the second print pass of a sheet, then the immediate successor of that sheet, and optionally one or more sheets following thereafter, may be utilized as spitting ink collectors and may than be discarded rather than being recirculated in the duplex loop.
In case of a printer in which the sheet flipping mechanism in the duplex loop cannot be bypassed, the orientation of the semi-finished sheets will be inverted each time they go through the sheet flipping mechanism. Consequently, the recirculated sheets will have to travel at least two rounds in the duplex loop in order for them to be again in the correct orientation for receiving the second image on the second side.
On the other hand, if the printer is of a type wherein the sheet flipping mechanism can be disabled or bypassed, then the recirculated sheets can be kept in their original orientation during the first round, so that they will reach the print engine in the correct orientation already after the first round, and, consequently, productivity will be enhanced.
Embodiment examples will now be described in conjunction with the drawings, wherein:
The fresh sheets 12 are separated from a supply stack (not shown) and are conveyed into the portion of the feed path 10 that is located between the switches 20 and 28. In this portion of the feed path, the semi-finished sheets 14 are interleaved with the fresh sheets 12 upstream of the print engine 16 and with the finished sheets 18 downstream of the print engine. In the present example, in every second print cycle of the print engine 16, a fresh sheet 12 is turned into a semi-finished sheet 14, and in the intervening print cycles a semi-finished sheet 14 will respectively be turned into a finished sheet 18, so that the number of semi-finished sheets in the duplex loop 24 can remain constant.
The sheets are numbered by sheet numbers s1-s16 in the order in which they are to be discharged via the discharge path 22. In the example considered here, the duplex loop 24 can accommodate up to fourteen semi-finished sheets 14 (s3-s16) only some of which have been shown in
In the example described here, it shall be assumed that the transport speed of the sheets in the duplex loop 24, more precisely, in the part from the switch 20 back to the switch 28, is only one half of the transport speed of the sheets in the feed path 10. Consequently, the interval between successive sheets in the duplex loop is only one half of the sheet-to-sheet interval in the feed path 10, which means that the gaps left by the finished sheets 18 that have been discharged are closed when the sheets enter into the duplex loop, and new gaps for accommodating the fresh sheets 12 are opened when the sheets return into the feed path 10. A reason for this design may be to provide more time for the ink on the semi-finished sheets to cure and for the sheets to cool down before they are fed to the print engine 16 again.
In the situation shown in
As is further shown in
If it could be taken for granted that the sheet defect error has not compromised the print quality achievable with the print engine 16 in subsequent print passes, then the print process could simply proceed with finishing sheet s3 and then printing the contents that were intended for the top side of sheet s16 onto the next fresh sheet s17. However, if it must be feared that the print quality has been compromised, then a recovery procedure for the print engine 16 is necessary. For example, the recovery procedure may comprise flushing the nozzles of the print heads by “spitting” ink onto the sheet 16 which will be discarded anyway or by printing recovery patterns on it. It is possible, however, that the time required for the recovery process is longer than the time gap between successive sheets in the feed path 10. Then, as has been illustrated in
A conventional error handling method would now require that sheet s3 is also discarded. Since this would mean that the corresponding page numbers (pages 5 and 6) would be missing in the stack 30, it would also be necessary to discard all the sheets s4-s15 that are presently in the duplex loop 24. i.e. to flush the entire duplex loop, and then to resume printing with printing the first image (page 5) on the first side of a fresh sheet and then, when the sheet has been flipped in the duplex loop, to print the second image (page 6) on the second side, so that the sheet, when discharged, could substitute the discarded sheet s3. This would mean that all the semi-finished sheets (s3 to s15 in this example) would be wasted.
In order to reduce this waste, the invention proposes a different method that will now be explained by reference to
In order to prevent the production of excessive waste, only the defective sheet s16 and sheet s17 will be discarded whereas the semi-finished sheets s3-s15 are kept in the duplex loop 24. Thus, in the print cycles subsequent to the one shown in
As is further shown in
Depending upon the design of the printer, it is possible that not only the sheet S17 is already in the feed path when the sheet defect error is detected, but there are two or more sheets already in the feed path. Then, these additional sheets would also have to be ejected and, optionally, could be used for spitting when passing underneath the print engine.
As can further be seen in
Thus, in this embodiment, the sheets that have been recirculated in the duplex loop 24 will have to make another round in the loop so that their orientations are flipped once more, as has been shown in
In this example, instead of discarding all the sheets s16 and s3-s15, only two sheets (s16 and s17) have been discarded, so that the amount of waste has been reduced significantly.
Note that it is not strictly necessary that printing of the second side of the semi-finished sheets s4, . . . , s15 resumes after the substitute sheet s18 has been printed. As soon as the recovery procedure for the print engine 16 has completed printing of the second side may resume with the first semi-finished sheet passing the print engine 16 provided the sheets are oriented correctly and the sheets are kept in the recirculation until earlier semi-finished sheets are also printed on their second side so that all of them can be discharged in their predetermined page sequence. From a productivity point of view, it makes no difference whether the second side of the semi-finished sheets is printed after the substitute sheet s18 has been printed or earlier because the delay caused by the recirculation is determined by the moment that the first semi-finished sheet s4 that is to be discharged has been printed and is ready for discharge.
In
The immediate successor of sheet s3, sheet s17 is a fresh sheet which does not yet bear any image. This sheet could be kept the duplex loop in the later stages of the error handling routine, but could also be replaced by another fresh sheet at any appropriate time. In the example shown here, the sheet s17 is used as a spitting collector in the recovery process for the print heads, as has been illustrated in
The situation illustrated in
It will be understood that the modification shown in
Although the examples provided in here often relate to ink jet print engines, these examples are merely chosen because the invention will have more impact in ink jet based printing processes. However, the invention may also be applied to other printing technologies in cut sheet printing, for example toner or liquid toner based technologies.
Number | Date | Country | Kind |
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20204779.1 | Oct 2020 | EP | regional |