The exemplary embodiment relates to a printing system. It finds particular application in connection with printing of color and monochrome images by utilizing separate paper delivery pathways which enables components of the printing system not in use at a particular time to be placed in a non-operational mode, and will be described with particular reference thereto. However, it will be appreciated that the embodiment finds application in other systems in which color and monochrome images are rendered.
Electronic printing systems typically employ an input terminal which receives images in digital form and conversion electronics for converting the image to image signals or pixels. The printing system may include a scanner for scanning image-bearing documents or be connected to a computer network which supplies the digital images. The signals are stored and are read out successively to a marking engine for formation of the images and transfer of the images to a print medium, such as paper. Printing systems have been developed which employ multiple marking engines for black, process (or full) color, and custom color (single color or monochrome) printing of selected pages within a print job.
In a typical xerographic marking device, such as a copier or printer, a photoconductive insulating member is charged to a uniform potential and thereafter exposed to a light image of an original document to be reproduced. The exposure discharges the photoconductive insulating surface in exposed or background areas and creates an electrostatic latent image on the member, which corresponds to the image areas contained within the document. Subsequently, the electrostatic latent image on the photoconductive insulating surface is made visible by developing the image with a developing material. Generally, the developing material comprises toner particles adhering triboelectrically to carrier granules. The developed image is subsequently transferred to a print medium, such as a sheet of paper. The fusing of the toner onto paper is generally accomplished by applying heat to the toner with a heated roller and application of pressure. In multi-color printing, successive latent images corresponding to different colors are recorded on the photoconductive surface and developed with toner of a complementary color. Each toner is associated with a separate housing and applied to the paper in sequence. The single color toner images are successively transferred to the copy paper to create a multi-layered toner image on the paper. The multi-layered toner image is then permanently affixed to the copy paper in the fusing process.
Recently, printing systems have been developed which include a plurality of marking engine modules. These systems enable high overall outputs to be achieved by printing portions of the same document on multiple printers. Such systems are commonly referred to as “tandem engine” printers, “parallel” printers, or “cluster printing” (in which an electronic print job may be split up for distributed higher productivity printing by different marking engines, such as separate printing of the color and monochrome pages).
In such machines, color marking engines which print with cyan, magenta, and yellow (CMY) as well as black (K) toners allow printing of both process color and black images on a single marking engine. However, the cost of producing black prints on a color marking engine is often higher than for a dedicated monochrome device. One reason for this is that the color components are often cycled, even during black printing. Although in some systems, the color components can be disabled during the production of monochrome prints, this tends to increase mechanical complexity to provide for retraction of the color components and to disengage their drives. Another reason for the higher cost is that the marking engine may provide a certain interdocument color toner throughput to control toner age in the system.
The following references, the disclosures of which are incorporated by reference in their entireties, relate to what have been variously called “tandem engine” printers, “parallel” printers, or “cluster printing” (in which an electronic print job may be split up for distributed higher productivity printing by different printers, such as separate printing of the color and monochrome pages), and “output merger” or “interposer” systems: U.S. Pat. No. 5,568,246 to Keller, et al., U.S. Pat. No. 4,587,532 to Asano, U.S. Pat. No. 5,570,172 to Acquaviva, U.S. Pat. No. 5,596,416 to Barry, et al.; U.S. Pat. No. 5,995,721 to Rourke et al; U.S. Pat. No. 4,579,446 to Fujino; U.S. Pat. No. 5,489,969 to Soler, et al.; a 1991 “Xerox Disclosure Journal” publication of November-December 1991, Vol. 16, No. 6, pp. 381-383 by Paul F. Morgan; and a Xerox Aug. 3, 2001 “TAX” publication product announcement entitled “Cluster Printing Solution Announced.”
Aspects of the present disclosure in embodiments thereof include a printing system and a method of printing. In one aspect, a printing system includes a first image applying component configured for applying at least a first of a plurality of colorants to print media for rendering an image. A second image applying component is configured for applying a second of the plurality of colorants to print media for rendering an image. A first pathway conveys print media between the first image applying component and the second image applying component, whereby in a first mode of printing of the printing system, an image rendered on the print media includes the first colorant and the second colorant. A second pathway which bypasses the first image applying component, for conveying print media on which the second image applying component applies the second colorant, whereby in a second mode of printing of the printing system, an image rendered on the print media includes the second colorant and not the first colorant.
In another aspect, a method of printing includes directing print media on which images are to be rendered with at least a first colorant and a second colorant to a first image applying component for applying at least the first colorant and conveying the print media with unfused first colorant to a second image applying component in series with the first image applying component for applying the second colorant. The method further includes directing print media on which images are to be rendered with the second colorant but not with the first colorant to the second image applying component for applying the second colorant, the print media bypassing the first image applying component.
In another aspect, a xerographic printing system includes a first image applying component which applies at least a first colorant to print media. A second image applying component applies at least a second colorant, different from the first colorant, to print media. A conveyor system is configured for selectively conveying print media with unfused first colorant between the first image applying component and the second image applying component and for selectively conveying print media to bypass one of the first and second image applying components, whereby colorant is applied by the other of the first and second image applying components. A fuser receives print media with unfused colorant from the first and second image applying components. The fuser is configured for fusing the first and second colorants.
Aspects of the exemplary embodiment, as disclosed herein, relate to a marking engine for a xerographic printing system which is capable of both monochrome (e.g., black) and process color printing and to a method of printing.
The term “marking engine” generally refers to a device for applying an image to print media. The exemplary printing system may include one or more marking engines and a variety of other components, such as finishers, paper feeders, and the like, and may be embodied as a copier, printer, bookmaking machine, facsimile machine, or a multifunction machine. “Print media” can be a usually flimsy physical sheet of paper, plastic, or other suitable physical print media substrate for images. A “print job” or “document” is normally a set of related sheets, usually one or more collated copy sets copied from a set of original print job sheets or electronic document page images, from a particular user, or otherwise related. An image generally may include information in electronic form which is to be rendered on the print media by the marking engine and may include text, graphics, pictures, and the like. A “finisher” can be any post-printing accessory device, such as a tray or trays, sorter, mailbox, inserter, interposer, folder, stapler, stacker, hole puncher, collater, stitcher, binder, envelope stuffer, postage machine, or the like. The operation of applying images to print media, for example, graphics, text, photographs, etc., is generally referred to herein as printing or marking.
With reference to
Image applying component 16 may be a process color image applying component which applies one or more colorants to the print media from a set of primary colorants, such as cyan, magenta, and yellow (C, M, Y) colorants from respective colorant sources 26, 28, 30. The image applying component 18 applies a different colorant from those in the set of colorants, generally a single colorant, black (K) in the illustrated embodiment, to the print media from a black colorant source 32 for black only (monochrome) printing or for multicolor printing (when combined with the C, M, and Y colorants). It is to be appreciated that although the black toner which comprises the black colorant may include some similar or identical pigments to those used in forming the C, M, or Y colorants, the black colorant is different to each of these colorants because its overall visible absorption spectrum is different, giving the colorant a different appearance to the observer's eye.
The conveyor system 24 includes a network of paper pathways including a main pathway 40, which conveys print media between the first and second image applying components 16, 18, and a bypass pathway 42, which allows one, but not both, of the image applying components (image applying component 16 in the embodiment of
Optionally, a decision gate 52 selectively directs print media from paper supply 14 into pathway 40 or pathway 42. The decision gate 52 may be under the control of a printer control system 54. In this way, a sheet which is to be monochrome (e.g., black only) printed can be directed by the control system into the bypass pathway 42, thereby bypassing the transfer region 46 for the primary colorants. The sheet returns to the main pathway 40 at the junction 50, downstream of the transfer region 46 for application of a monochrome image in the transfer region 48. The applied image is then fused by the fuser 20. Optionally, a second decision gate 55 is provided in the junction 50. In a first position (shown in
During monochrome printing, the image applying component 16 can be placed in a non-operational, e.g., standby mode, in which some or all of its operating components are placed in a state where they suffer less wear and/or operate at lower cost per page than when the sheets are directed through transfer region 46. As a result, the cost per page of monochrome printing is reduced and is more comparable with the costs incurred when a black only printing system is used.
When a sheet is to be printed in color, with one or more of the C,M,Y colorants, the control system 54 actuates the decision gate 52 to direct the sheet onto pathway 40, upstream of the transfer region 46. In this way, an image formed from one or more of the C, M, Y colorants is applied at the transfer region 46. The control system 54 may also set the gate 55 in its first position. The sheet continues without intermediate fusing, to transfer region 48, where the unfused image applied at the transfer region 46 may be supplemented with black colorant to form an image with up to four colorants C, M, Y, and K.
To minimize the risk of disturbing the unfused image between the first transfer region 46 and the fuser 20, the distance d between the first and second transfer regions 46, 48 is, in one embodiment, as short as conveniently possible and may include few or no drive members 44 which may cause disturbance to the sheet. In one embodiment, d is less than a length of a sheet in the process direction. For example. d may be less than about 21 cm, e.g., about 20 cm or less for conventional letter size paper which is processed with its shortest dimension (about 21.5 cm) aligned with the process direction. This allows one end of the sheet to be engaged in transfer nip 47 while the other end is simultaneously engaged by transfer nip 45. In this way, accurate registration of a black component of an image can be made with the color component(s) applied upstream. Alternatively for example where distance d is greater than a length of the sheet, a sheet registration system (not shown) may be provided intermediate the transfer nips 45, 47 to ensure correct alignment of the images on the sheet. Such registration systems are known and typically include a sensor for sensing a recognizable feature of the sheet, such as a forward end and drive members for adjusting the position of the sheet or its speed.
The control system 54 may include a processing component 56, which receives a print job comprising images to be rendered from a digital image source 58. The processing component 56 reviews the images to be rendered and for each page, determines whether the page is to be monochrome printed or will require color printing. The control system 54 schedules the operation of the decision gates 52, 55 and the transfer of the sheets through the printing system 10 such that those pages which require only monochrome printing bypass the color transfer region 46 via pathway 42 and those sheets which require color printing are directed along pathway 40. The image source 58 can be a built-in optical scanner which can be used to scan a document such as book pages, a stack of printed pages, or the like, to create a digital image of the scanned document that is reproduced by printing operations performed by the printing system 10. Alternatively, the image source 58 may include an electronic link. For example, a print job can be electronically delivered to the control system 54 via a wired or wireless connection to a digital network (not shown) that interconnects, for example, personal computers or other digital devices. For example, a network user operating word processing software running on a computer may select to print a word processing document on the printing system 10, thus generating the print job, or an external scanner connected to the network may provide the print job in electronic form. The digital network can be a local area network such as a wired Ethernet, a wireless local area network (WLAN), the Internet, some combination thereof, or the like. Moreover, it is contemplated that print jobs may be delivered to the printing system 10 in other ways, such as by using an optical disk reader (not illustrated) built into the printing system 10, or using a dedicated computer connected only to the printing system 10.
When a monochrome print job, or monochrome pages of a print job, are to be printed, the control system 54 communicates this information to the first image applying component 16. This causes the first image applying component to cycle down to a non-operational state when, for example, a preselected minimum number of sheets are scheduled to bypass the transfer region 46. In a non-printing period, one or more of the functions of the first image applying component 16 are typically switched off or allowed to go into a “non-operational” mode where the printer is not ready for printing, such as a low energy mode. It will be appreciated that the first image applying component 16 may have different levels of operation, when more or less of the components are brought to a standby state or to different standby states, depending on the number of sheets which are to bypass the transfer region 46. The determination of what standby level the first image applying component 16 is placed in may be determined by suitable algorithms in either the control system 54 or associated with the first image applying component 16. For example, the control system 54 determines how long the period between marking operations will be and determines whether the first image applying component 16 should completely cycle down, or only shut down some of its operational functions. Where the control system determines that the first image applying component 16 will be required again in a relatively short time, the first image applying component 16 may be placed in an intermediate low energy mode, where some, but not all the functions are switched to a standby mode. This is because some of the marking engine components are more subject to damage than others when not in continuous use. Some components may take longer to be brought to a non-operational mode or returned to an operational mode and thus it is only beneficial to begin cycling these components down when a relatively long period of inactivity is scheduled. For each component, there is generally a predetermined period, after which the component is switched to a non-operational mode to avoid potential damage to the image applying component/reduce overall printing costs.
Optionally, an inversion path 60 is provided by which once printed media is inverted for duplex (two sided) printing in the marking engine 12. In the illustrated embodiment, the inversion path 60 is accessed from the first pathway 40, downstream of the fuser assembly 20, by means of a decision gate 62, and connects with the pathway 40 upstream of the decision gate 52 and upstream of the transfer region 46. The inversion path 60 includes an inverter 64, which inverts the sheet to present a second side to the transfer region 46 and or 48 for color/black only printing.
In other embodiments, the first image applying component 16 may be configured as for
With reference now to
As illustrated in
In the standby (non-operational) mode, during black-only printing, one or more of the xerographic subsystems 90, 92, 94, 98, and optionally also transfer belt 100 of image applying component 16 may be placed in a standby mode. For example, the photoreceptor 90 and/or transfer belt 100 may be stopped or slowed down, the power to the corotrons 92, 98 and/or exposure station 94 may be switched off or reduced, and the agitators (not shown) which normally churn the toner and carrier material in developer housing 96 may be switched off.
It will be appreciated that the printing system of
In yet another embodiment, the xerographic components 92, 94, 96, for the three colorants C, M, and Y are arranged around the same photoreceptor 90 and transferred to the print media from the photoreceptor at the transfer region 46 by a single transfer corotron 98. In this embodiment, the transfer belts 100, 101 are not required.
The illustrated marking engine 12 employs xerographic printing technology, in which an electrostatic image is formed and coated with a toner material, and then transferred and fused to paper or another print medium by application of heat and/or pressure. However, marking engines employing other printing technologies can be provided, such as marking engines employing ink jet transfer, thermal impact printing, or the like in which the fuser assembly serves to dry or otherwise fix the ink to the sheet.
It is to be appreciated that the marking engine 12 can include an input/output interface, a memory, a marking cartridge platform, a marking driver, a function switch, a controller and a self-diagnostic unit, all of which can be interconnected by a data/control bus. In this embodiment, the control system 54 may control the operations of each of these components.
The printing system 10 executes print jobs. Print job execution involves printing images, such as selected text, line graphics, photographs, MICR notation, and the like on front, back, or front and back sides or pages of one or more sheets of paper or other print media. Some sheets may be left completely blank. Some sheets may have both color and monochrome images. Execution of the print job may also involve collating the sheets in a certain order. Still further, the print job may include folding, stapling, punching holes into, or otherwise physically manipulating or binding the sheets. The printing, finishing, paper handing, and other processing operations that can be executed by the printing system 10 are determined by the capabilities of the paper source 14, marking engine(s) 12, and finisher 22 of the printing system 10. In some embodiments, the printing system 10 may be a cluster of networked or otherwise logically interconnected image applying components, each having its own associated print media source.
The printing systems of
In the marking engine 12 of
In the marking engine of
It will be appreciated that various of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems or applications. Also that various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.
The following applications, the disclosures of each being totally incorporated herein by reference, are mentioned: Application Ser. No. 11/212,367 (Attorney Docket No. 20031830-US-NP), filed Aug. 26, 2005, entitled “PRINTING SYSTEM,” by David G. Anderson, et al., and claiming priority to U.S. Provisional Application Ser. No. 60/631,651, filed Nov. 30, 2004, entitled “TIGHTLY INTEGRATED PARALLEL PRINTING ARCHITECTURE MAKING USE OF COMBINED COLOR AND MONOCHROME ENGINES”; U.S. application Ser. No. 10/761,522 (Attorney Docket A2423-US-NP), filed Jan. 21, 2004, entitled “HIGH RATE PRINT MERGING AND FINISHING SYSTEM FOR PARALLEL PRINTING,” by Barry P. Mandel, et al.; U.S. application Ser. No. 10/881,619 (Attorney Docket A0723-US-NP), filed Jun. 30, 2004, entitled “FLEXIBLE PAPER PATH USING MULTIDIRECTIONAL PATH MODULES,” by Daniel G. Bobrow; U.S. application Ser. No. 10/917,768 (Attorney Docket 20040184-US-NP), filed Aug. 13, 2004, entitled “PARALLEL PRINTING ARCHITECTURE CONSISTING OF CONTAINERIZED IMAGE MARKING ENGINES AND MEDIA FEEDER MODULES,” by Robert M. Lofthus, et al.; U.S. application Ser. No. 10/924,106 (Attorney Docket A4050-US-NP), filed Aug. 23, 2004, entitled “PRINTING SYSTEM WITH HORIZONTAL HIGHWAY AND SINGLE PASS DUPLEX,” by Robert M. Lofthus, et al.; U.S. application Ser. No. 11/090,498 (Attorney Docket 20040619-US-NP), filed Mar. 25, 2005, entitled “INVERTER WITH RETURN/BYPASS PAPER PATH,” by Robert A. Clark; U.S. application Ser. No. 11/093,229 (Attorney Docket 20040677-US-NP), filed Mar. 29, 2005, entitled “PRINTING SYSTEM,” by Paul C. Julien; U.S. application Ser. No. 11/094,998 (Attorney Docket 20031520-US-NP), filed Mar. 31, 2005, entitled “PARALLEL PRINTING ARCHITECTURE WITH PARALLEL HORIZONTAL PRINTING MODULES,” by Steven R. Moore, et al.; U.S. application Ser. No. 11/109,558 (Attorney Docket 19971059-US-NP), filed Apr. 19, 2005, entitled “SYSTEMS AND METHODS FOR REDUCING IMAGE REGISTRATION ERRORS;” by Michael R. Furst, et al.; U.S. application Ser. No. 11/109,566 (Attorney Docket 20032019-US-NP), filed Apr. 19, 2005, entitled “MEDIA TRANSPORT SYSTEM,” by Barry P. Mandel, et al.; and U.S. application Ser. No. 11/152,275 (Attorney Docket 20040506-US-NP), filed Jun. 14, 2005, entitled “WARM-UP OF MULTIPLE INTEGRATED MARKING ENGINES,” by Bryan J. Roof, et al.