Preferred embodiments of the present invention will now be described in detail in accordance with the accompanying drawings.
In this specification, the terms “print” and “printing” not only include the formation of significant information such as characters and graphics, but also broadly includes the formation of images, figures, patterns, and the like on a print medium, or the processing of the medium, regardless of whether they are significant or insignificant and whether they are so visualized as to be visually perceivable by humans.
Also, the term “print medium” not only includes a paper sheet used in common printing apparatuses, but also broadly includes materials, such as cloth, a plastic film, a metal plate, glass, ceramics, wood, and leather, capable of accepting ink.
Furthermore, the term “ink” (to be also referred to as a “liquid” hereinafter) should be extensively interpreted similar to the definition of “print” described above. That is, “ink” includes a liquid which, when applied onto a print medium, can form images, figures, patterns, and the like, can process the print medium, and can process ink (e.g., can solidify or insolubilize a coloring agent contained in ink applied to the print medium).
Furthermore, unless otherwise stated, the term “nozzle” generally means a set of a discharge orifice, a liquid channel connected to the orifice and an element to generate energy utilized for ink discharge.
The arrangement of the printing apparatus will be described next with reference to
A printing apparatus 1 shown in
(A) Feeding Portion
A feeding portion 2 shown in
A feed tray (not shown) to hold the stacked printing media is attached to the base 20 or housing. The slidably retractable feed tray is pulled out for use.
The feed roller 28 is columnar and has an arc-shaped section. A motor shared by a cleaning unit provided in the feeding portion 2 transmits a driving force to the feed roller 28 via a driving transmitting gear (not shown) and a planet gear (not shown).
A movable side guide 23 is provided on the pressure plate 21 to limit the stack position of printing media. The pressure plate 21 can rotate about a rotating shaft coupled to the base 20. A platen spring (not shown) biases the pressure plate 21 to the feed roller 28. The pressure plate 21 has, on its part facing the feed roller 28, a separation sheet (not shown) made of a material with a large friction coefficient, e.g., artificial leather to prevent erroneous multiple sheets conveyance when the stacked printing media are going to run out. The pressure plate 21 can abut against the feed roller 28 or separate from it via a pressure plate cam (not shown).
The separation roller 241 has a clutch spring (not shown). With a predetermined load or more, the attachment portion of the separation roller 241 can rotate.
In a normal standby state, the stack port is closed not to feed the stacked printing media into the printing apparatus. When feeding starts in this state, the motor is driven to make the separation roller 241 abut against the feed roller 28. The pressure plate 21 also abuts against the feed roller 28. Feeding of the printing media starts in this state. Only a predetermined number of printing media are fed to a nip portion formed by the feed roller 28 and the separation roller 241. The fed printing media are separated at the nip portion. Only the printing medium at the top is fed into the printing apparatus.
When the printing medium reaches a conveyance roller 36 and pinch rollers 37, the pressure plate cam (not shown) returns the pressure plate 21 to the initial position. At this time, the printing medium that has reached the nip portion formed by the feed roller 28 and the separation roller 241 can return to the stack position.
(B) Conveyance Portion
The conveyance portion is attached to a chassis 11 made of a bent metal sheet. The conveyance portion has the conveyance roller 36 for conveying a printing medium, and a PE sensor 32. The conveyance roller 36 is made of a metal shaft with a coating of ceramic micro-particles. The conveyance roller 36 is received by bearings at its metal parts of both ends and attached to the chassis 11. A conveyance roller tension spring (not shown) is inserted between the conveyance roller 36 and each bearing to bias the conveyance roller 36 and apply a predetermined load to it during rotation so that stable conveyance is possible.
The plurality of pinch rollers 37 are abut against and follow the conveyance roller 36. A pinch roller holder (not shown) holds the pinch rollers 37. A pinch roller spring (not shown) biases the pinch rollers 37 to press them against the conveyance roller 36 so that a printing medium conveyance force is generated. The pinch rollers 37 rotate about the rotating shaft of the pinch roller holder, which is attached to the bearings of the chassis 11. A platen 34 is disposed at the entrance of the conveyance portion where a printing medium arrives. The platen 34 is attached to the chassis 11 and positioned.
In the above arrangement, a printing medium fed to the conveyance portion is guided by the pinch roller holder (not shown) and a paper guide flapper and fed to the roller pair of the conveyance roller 36 and pinch rollers 37. At this time, the PE sensor 32 detects the leading edge of the conveyed printing medium whereby the print position of the printing medium is determined. As a conveyance motor (not shown) rotates the pair of rollers 36 and 37, the printing medium is conveyed on the platen 34. Ribs serving as a conveyance reference plane are formed on the platen 34 to manage the gap to the printhead and suppress wave of the printing medium together with the discharge portion to be described later.
As shown in
A printhead 7 used for forming an image on the basis of image information is provided downstream in the printing medium conveyance direction of the conveyance roller 36.
As the printhead 7, an inkjet printhead including color ink tanks 71 that are individually exchangeable is used. The printhead 7 discharges ink from nozzles to form an image on a printing medium as the ink film-boils upon receiving heat from, e.g., a heater and creates bubbles which grow or shrink to change the pressure. At this time, the platen 34 holds the printing medium to maintain a predetermined distance between its print surface and the nozzles.
An absorbent material 344 is provided on the platen 34 to absorb ink overflowing from the edge of a printing medium in full print (marginless print). The absorbent material 344 absorbs ink overflowing from all four edges of a printing medium.
(C) Carriage Portion
A carriage portion 5 has a carriage 50 to which the printhead 7 is attached. A guide shaft 52 that reciprocally scans in a perpendicular direction (different direction) to the printing medium conveyance direction and a guide rail (not shown) which holds the rear end of the carriage 50 to maintain the gap between the printhead 7 and a printing medium support the carriage 50. The guide shaft 52 is attached to the chassis 11. The guide rail is integrated with the chassis 11.
A carriage motor 54 attached to the chassis 11 drives the carriage 50 via a timing belt 541. The timing belt 541 connects to the carriage 50 via a damper made of, e.g., rubber and reduces the density unevenness in images by attenuating vibrations of the carriage motor 54 and the like. A cord strip 561 with markings formed at a pitch of 150 to 300 lpi is provided parallel to the timing belt 541 to detect the position of the carriage 50. An encoder sensor (not shown) to read the markings is provided on a carriage substrate (not shown) provided in the carriage 50. The carriage 50 also has a flexible substrate 57 to transmit various kinds of control signals and print signals from a control circuit (to be described later) to the printhead 7.
A head set lever 51 is provided to fix the printhead 7 to the carriage 50. The printhead 7 is fixed to the carriage 50 by turning the head set lever 51 about its fulcrum.
To form an image on a printing medium, the pair of rollers 36 and 37 convey a printing medium to the ink discharge position of the printhead 7 along the printing medium conveyance direction. Simultaneously, the carriage motor 54 moves the carriage 50 to the ink discharge position along the carriage moving direction. The printhead 7 discharges ink to the printing medium in accordance with a control signal from the control circuit, thereby forming an image.
(D) Discharge Portion
The discharge portion includes two discharge rollers 40 and 41, a spur (not shown) that abuts against the discharge rollers 40 and 41 at a predetermined pressure and rotates with them, and a series of gears to transmit the driving force of the conveyance roller to the discharge rollers 40 and 41. The discharge rollers 40 and 41 are attached to the platen 34. The discharge roller 40 has a plurality of rubber parts on its metal shaft.
As shown in
The spur is attached to a spur holder 43.
With the above-described arrangement, the printing medium printed by the printhead 7 is pinched at the nip between the spur and the discharge roller 41, conveyed, and discharged to a discharge tray 46. The discharge tray 46 is retractable into a front cover 95. For use, the discharge tray 46 is pulled out. The discharge tray 46 has an ascending slope and vertical projections at two ends to easily stack discharged printing media and prevent friction of printed surfaces.
As shown in
Referring to
A switch group 620 includes a power switch 621, a print switch 622 that gives the instruction to start printing, and a recovery switch 623 that gives the instruction to activate a process (recovery process) to maintain high ink discharge performance of the printhead 7. The printing apparatus receives an operator's instruction inputs from these switches. A sensor group 630 includes a position sensor 631 such as a photocoupler to detect a home position, and a temperature sensor 632 provided at an appropriate position of the printing apparatus to detect the ambient temperature. Additionally, the A/D converter 606 receives the output from the encoder sensor 363 that detects the position of the conveyance roller 36 and the output from the encoder sensor 403 that detects the position of the discharge roller 40.
A carriage motor driver 640 drives the carriage motor 54 to reciprocally scan the carriage 50. A conveyance motor driver 642 drives the conveyance motor 35 to convey a printing medium.
In print scan of the printhead 7, the ASIC 603 transfers the drive data (DATA) of printing elements (discharge heaters) to the printhead while directly accessing a storage area of the RAM 604.
In the arrangement shown in
An example will be described next in detail, in which printing medium conveyance control is performed by simultaneously inputting the outputs from a plurality of encoder sensors provided on the conveyance mechanism of a printing apparatus, comparing the input results, and assuming the state of a printing medium on the basis of the comparison.
As shown in
In this embodiment, the PE sensor 32 detects the tail end position of the printing medium P. Actually, the PE sensor 32 detects the fact that the front end of the printing medium P contacts the PE sensor lever 321 provided on the pinch roller holder that holds the pinch rollers 37, or the fact that the tail end of the printing medium is in non-contact with the PE sensor lever 321.
As shown in
When the tail end of the printing medium P is located within the range of about 10 mm before and after the nip between the conveyance roller 36 and the pinch roller 37, conveyance control is made on the basis of the outputs from the two encoder sensors 363 and 403. This area is referred to as a cooperative control area.
In this area, the outputs from the two encoder sensors 363 and 403 are inputted. The stop position (conveyance position) of the printing medium is calculated on the basis of the two input data. The encoder sensors 363 and 403 have misalignment upon attaching these to the printing apparatus. Hence, the limiting resolution is raised by time multiplication to an extent that printing quality will not be affected, thereby correcting the positions of the encoders. In the cooperative control area, if the difference between the outputs of the two encoder sensors 363 and 403 has a predetermined amount or less, it is assumed that printing can be performed without any problem. However, for example, if the tail end of the printing medium P is located closest to the nip between the conveyance roller 36 and the pinch roller 37, the wedge effect of the nip might result in conveying the printing medium P to the discharge roller 40 downstream in the conveyance direction by an amount equal to or smaller than the backlash of a series of drive gears. In this case, the detection result of the encoder sensor 363 and that of the encoder sensor 403 (i.e., the conveyance amount of the conveyance roller 36 and that of the discharge roller 40) have a difference.
This situation and its countermeasure will be explained with reference to
Normally, the output difference between the encoder sensors 363 and 403 occurs due to, e.g., the eccentric amounts of the rollers, and has a predetermined amount or less.
The encoder sensor 403 can detect this positional shift.
The stop position of the printing medium can be corrected by rotating the discharge roller 40 in the reverse direction, as shown in
After the tail end of the printing medium P separates from the nip between the conveyance roller 36 and the pinch roller 37 by about 10 mm, control is made in the control area of the encoder sensor 403, as shown in
In this embodiment, since the discharge roller 40 that directly conveys the printing medium P is controlled by using the cord wheel 402 and encoder sensor 403 directly connected to the discharge roller 40, accurate conveyance can be implemented.
According to the above-described embodiment, it is possible to perform optimum conveyance control by simultaneously inputting the outputs from two encoder sensors, comparing the input results, and assuming the conveyance state of the printing medium on the basis of the comparison result in a predetermined area on printing medium conveyance. This improves the conveyance accuracy and implements printing of an image with higher quality.
Also, appropriate conveyance control is possible even when the tail end of the printing medium P is located closest to the nip between the conveyance roller 36 and the pinch roller 37. Hence, complicated control to prevent the tail end of the printing medium P from stopping at the nip, as disclosed in Japanese Patent Publication Laid-Open No. 2002-254736, is unnecessary. Since the restrictions on use nozzles of the printhead for nozzle shift in the prior art are also eliminated, all nozzles become available, and this contributes to high-speed printing. Complicated conveyance control of the tail end portion of the printing medium need not be performed, unlike the prior art. It is, therefore, possible to print on the tail end satisfactorily.
In the above embodiment, conveyance control when the tail end of the printing medium P passes through the nip between the conveyance roller 36 and the pinch roller 37 has been described. In the following embodiment, conveyance control when a discharge roller 40 and a spur grip the front end of a printing medium P will be explained.
In this embodiment, when the discharge roller 40 and spur grip the front end of the printing medium P, position information from two encoder sensors 363 and 403 is input. A change in the behavior of the printing medium P is estimated and corrected on the basis of the position information difference.
As shown in
When the front end of the printing medium P is located within the range of about 10 mm before and after the nip between the discharge roller 40 and the spur 42, conveyance is controlled in the cooperative control area where conveyance control is performed on the basis of the outputs from the two encoder sensors 363 and 403. In this area, the outputs from the two encoder sensors 363 and 403 are inputted. The stop position (conveyance position) is calculated on the basis of the two position data. The encoder sensors 363 and 403 have misalignment upon attaching these to the printing apparatus. Hence, the limiting resolution is raised by time multiplication to an extent that printing quality will not be affected, thereby correcting the positions of the encoders.
In the cooperative control area, if the difference between the outputs of the encoder sensors 363 and 403 has a predetermined amount or less, it is assumed that printing is progressing without any problem.
However, for example, if the front end of the printing medium P reaches the nip between the discharge roller 40 and the spur 42, or the printing medium P has, e.g., a curl, the lift of the printing medium P is canceled after it is gripped at the nip between the discharge roller 40 and the spur 42. Consequently, the printing medium P is conveyed as it rotates the discharge roller 40. In this case, the output result of the encoder sensor 363 and that of the encoder sensor 403 (i.e., the conveyance amount of a conveyance roller 36 and that of the discharge roller 40) have a difference.
This situation and its countermeasure will be explained with reference to
As shown in
The encoder sensor 403 can detect this shift amount.
Hence, in this embodiment, the print position can be corrected by rotating the conveyance roller 36 and discharge roller 40 in the reverse direction, as shown in
After the front end of the printing medium P separates from the nip between the discharge roller 40 and the spur 42 by about 10 mm, control is made in the conveyance control area based on only the output from the encoder sensor 363. In this area, conveyance control is performed on the basis of only the output from the encoder sensor 363 to convey the printing medium P by a predetermined amount and stop it at a predetermined position.
According to the above-described embodiment, it is possible to perform optimum conveyance control by simultaneously using the outputs from a plurality of encoder sensors, comparing the output results, and estimating the state of the printing medium on the basis of the comparison result even when the front end of the printing medium reaches the nip between the discharge roller and the spur. This implements printing of an image with higher quality.
While the present invention has been described with references to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2006-227015, filed Aug. 23, 2006, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
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2006-227015 | Aug 2006 | JP | national |