Patent Application
20070070168
The present invention relates to thermal printers of type that apply material from a donor web to a receiver web in order to form images on the receiver web.
In thermal printing, it is generally well known to render images by heating and pressing one or more donor materials such as a dye, colorant or other coating against a receiver medium. The donor materials are provided in sized donor patches on a movable web known as a donor ribbon. The donor patches are organized on the ribbon into donor sets, each set containing all of the donor patches that are to be used to record an image on the receiver medium. For full color images, multiple color dye patches can be used, such as yellow, magenta and cyan donor dye patches. Arrangements of other color patches can be used in like fashion within a donor set. Additionally, each donor set can include an overcoat or sealant layer.
Thermal printers offer a wide range of advantages in photographic printing including the provision of truly continuous tone scale variation and the ability to deposit, as a part of the printing process a protective overcoat layer to protect the images formed thereby from mechanical and environmental damage. Accordingly, the most popular photographic kiosks and home photo printers currently use thermal printing technology.
There is, however, a desire to have such printers print images at a faster rate. This requires that such thermal printers transfer donor material at a higher rate of speed, which in turn, allows a reduced time period for donor material transfer—per picture image element (pixel). Accordingly, the thermal load that must be applied to cause donor material to be transferred to the receiver medium must be delivered in this reduced time period. This requires an increase in the temperatures that are delivered to the donor ribbon. These increased temperatures can negatively impact the printing process.
What is needed therefore is a control system for use with a thermal printer that allows a high rate of printing while preventing overheating of the printhead particularly during extended printing jobs.
What is also needed is a control system that can control such temperatures without requiring extended print delays between individual images within the printing order as consumers and even some retailers can confuse such delays with an end of the process of printing the print order and thus can erroneously package and deliver only those images that were printed before the extended print delay.
In one aspect of the invention, a thermal printer is provided. The thermal printer comprises a donor transport system having a motorized system for advancing a donor web relative to a printhead, the donor web having patches of donor material including at least one colored donor material; a receiver transport system having a motorized system for advancing a receiver web relative to the printhead; the printhead being able to actuate heat and transfer donor material from the donor web to the receiver web; a first thermal sensor adapted to sense thermal energy indicative of the temperature of the printhead and to generate a primary thermal feedback signal representative of the temperature of the printhead; a controller for controlling the operation of the donor transport system, the receiver transport system, and the printhead so as to enable imagewise transfer of donor material onto the receiver web to form a sequence of at least two images, the controller being operable to interpose at least one programmed delay between the printing of at least two of the images in the sequence; wherein the controller determines the length of each programmed delay by using the temperature of the thermal printhead and a time rate of cooling of the printhead in a manner that is adapted to provide a sufficient cooling time to prevent the printhead from reaching a maximum printhead temperature during printing of the sequence of images.
In another aspect of the invention, a method is provided for operating a printing system which applies donor material from donor patches on a donor web to a receiver medium using a thermal printhead that generates heat. In this aspect, the method comprises the steps of: receiving a print order requesting the printing of a quantity of images; determining a temperature of the printhead printing a designated number of the quantity of the images in a sequence; determining a length of time of a programmed delay; delaying the printing for the determined length of time of the programmed delay; and printing remaining images from the quantity of images; wherein the length of each programmed delay is determined by using the temperature of the thermal printhead and a time rate of cooling of the printhead and is determined in a manner that provides a sufficient cooling time to prevent the printhead from reaching a maximum printhead temperature during printing of the sequence of images.
In still another aspect of the invention, a method is provided for operating a printing system which applies donor material from donor patches on a donor web to a receiver medium using a thermal printhead that generates heat. In this aspect, the method comprises the steps of: receiving a print order requesting the printing of a quantity of images; determining a temperature of the printhead organizing the quantity of images requested in the print order into sequences of a determined number of images; and printing the sequences of images with a programmed delay between each sequence; wherein the length of each programmed delay is determined based upon the temperature of the thermal printhead and a time rate of cooling of the printhead and is calibrated in a manner that provides provide a sufficient cooling time to prevent the printhead from reaching a maximum printhead temperature during the printing of a subsequent one of the sequences.
Thermal resistors 43 are adapted to generate heat in proportion to an amount of electrical energy that passes through thermal resistors 43. During printing, controller 20 transmits signals to a circuit board 51 to which thermal resistors 43 are connected causing different amounts of electrical energy to be applied to thermal resistors 43 so as to selectively heat donor web 30 in a manner that is intended to cause donor material from donor patches 34, 36, 38, and 40 to be applied to receiver web 26 in a desirable manner.
As is shown in
A first color is printed in the conventional direction, from right to left as seen by the viewer in
Controller 20 also actuates receiver medium take up roller 42 and receiver medium supply roller 44 so that image receiving area 52 of receiver medium 26 is positioned with respect to the printhead 22. In the embodiment illustrated, image-receiving area 52 is defined by a leading edge LER and a trailing edge TER on receiver medium 26. Donor web 30 and receiver medium 26 are positioned so that leading edge LED of yellow donor patch 34.1 is registered at printhead 22 with leading edge LER of image receiving area 52. Controller 20 then causes a motor or other conventional structure to (not shown) lower printhead 22 so that a lower surface of donor web 30 engages receiver medium 26 which is supported by platen roller 46. This creates a pressure holding donor web 30 against receiver medium 26.
Controller 20 then actuates receiver medium take-up roller 42, receiver medium supply roller 44, donor web take-up roller 48 and donor web supply roller 50 to move receiver medium 26 and donor web 30 together past the printhead 22. Concurrently, controller 20 selectively operates heater elements in printhead 22 to transfer donor material yellow donor patch 34.1 to receiver medium 26.
As donor web 30 and receiver medium 26 leave the printhead 22, a stripping plate 54 separates donor web 30 from receiver medium 26. Donor web 30 continues over idler roller 56 toward the donor web take-up roller 48. As shown in
Controller 20 operates the printer 18 based upon input signals from a user input system 62, an output system 64, a memory 68, a communication system 74 and sensor system 80. User input system 62 can comprise any form of transducer or other device capable of receiving an input from a user and converting this input into a form that can be used by controller 20. For example, user input system 62 can comprise a touch screen input, a touch pad input, a 4-way switch, a 6-way switch, an 8-way switch, a stylus system, a trackball system, a joystick system, a voice recognition system, a gesture recognition system or other such systems. An output system 64, such as a display, is optionally provided and can be used by controller 20 to provide human perceptible signals for feedback, informational or other purposes.
Data including, but not limited to, control programs, digital images and metadata can also be stored in memory 68. Memory 68 can take many forms and can include without limitation conventional memory devices including solid state, magnetic, optical or other data storage devices. In the embodiment of
In the embodiment shown in
Sensor system 80 includes circuits and systems that are adapted to detect conditions within printer 18 and, optionally, in the environment surrounding printer 18 and to convert this information into a form that can be used by controller 20 in governing printing operations. Sensor system 80 can take a wide variety of forms depending on the type of media therein and the operating environment in which printer 18 is to be used.
In the embodiment of
During a full image printing operation, controller 20 causes donor web 30 to be advanced in a predetermined pattern of distances so as to cause a leading edge of each of the first donor patches 34.1, 36.1, 38.1 and 40.1 to be properly positioned relative to the image receiving area 52 at the start each printing process. Controller 20 can optionally be adapted to achieve such positioning by precise control of the movement of donor web 30 using a stepper type motor for motorizing donor web take up roller 48 or donor web supply roller 50 or by using a movement sensor 86 that can detect movement of donor web 30. In one example an arrangement using a movement sensor 84, a follower wheel 88 is provided that engages donor web 30 and moves therewith. Follower wheel 88 can have surface features that are optically, magnetically or electronically sensed by movement sensor 86. One example of this is a follower wheel 88 that has markings thereon indicative of an extent of movement of donor web 30 and a movement sensor 86 that has a light sensor that can sense light reflected by the markings. In other optional embodiments, perforations, cutouts or other routine and detectable indicia can be incorporated onto donor web 30 in a manner that enables movement sensor 84 to provide an indication of the extent of movement of the donor web 30.
Alternatively, donor position sensor 82 can also optionally be adapted to sense the color of donor patches on donor web 30 and can provide color signals to controller 20. In this alternative, controller 20 is programmed or otherwise adapted to detect a color that is known to be found in the first donor patch, e.g. yellow donor patch 34.1 in a donor patch set such as first donor patch set 32.1. When the first color is detected, controller 20 can determine that donor web 30 is positioned proximate to the start of a donor patch set.
In the embodiment illustrated in
As is also shown in the embodiment of
The print order contains instructions sufficient for controller 20 to initiate printing operations. Accordingly, each print order generally provides sufficient information from which controller 20 can determine what images are to be printed and the quantity of images to be printed. Typically, the print order will provide image data for the images to be printed, however, the print order can simply designate a location at which the printer can obtain the image data.
Controller 20 then determines a temperature of printhead 22 (step 102) based upon the first feedback signal from first temperature sensor 90. In the embodiment of
Controller 20 will have programming that indicates a maximum printhead temperature above which printhead 22 is not to be used for printing (step 104). When the temperature of printhead 22 is at or above the maximum printing (step 104) will be delayed (step 106) until the temperature of printhead 22 is reduced to a temperature below the maximum printhead temperature (step 104).
Where printhead 22 is within a range of a ready temperatures, controller 20 can cause the printing of the images called for in the print order (step 108). Under these circumstances, controller 20 causes a sequence of the images from the print order to be printed in a sequential manner (step 110). After a designated number of images have been printed in sequence, controller 20 interposes a programmed delay before printing additional images (step 112). The programmed delay permits periodic cooling of printhead 22 so that printhead 22 can be used to print more images without reaching the maximum temperature for printhead 22. As will be discussed below, the duration of the programmed delay can vary significantly. However, when printhead temperatures are within the range of ready temperatures the length of the programmed delay is minimized to provide high print speed. The designated number of images printed between programmed delays can be predetermined, can be user selected, or can be automatically determined by controller 20. During such printing the temperature of printhead 22 is monitored by controller 22 to determine whether the temperature of printhead 22 has been elevated so that it is within a range of elevated temperatures (step 108).
Likewise, when it is determined that printhead 22 is within a range of elevated temperatures (step 108), controller 20 causes printhead 22 to execute at least one programmed delay between at least two of the successive prints of the print order. However, when the temperature of the printhead 22 is within the range of elevated temperatures, controller 20 determines a length of an extended programmed delay (step 122) and executes an extended programmed delay (step 124). Controller 20 determines the length of the programmed delay based upon the temperature of printhead 22 and a time rate of cooling of printhead 22.
The time rate of cooling of printhead 22 is a function of the thermal transfer characteristics of printhead 22, including but not limited to, thermal resistors 43 and structures positioning and contacting thermal resistors 43 such as, where applicable, ceramic substrate 45 and heat sink 47. It will be appreciated that the time rate of cooling of printhead 22 will also be inversely proportional to an ambient temperature into which heat from printhead 22 is radiated. This ambient temperature can vary significantly depending upon the operational environment of printer 18, thus it is necessary to provide a controller 20 with an ability to determine the time rate of cooling of printhead 22 so that unnecessary cooling time is not interposed during the printing of the images of a print order.
In the embodiment illustrated in
Table I illustrates one example of a look up table that illustrates the way in which ambient temperature and the length of a programmed delay are related. As can be seen in Table I, when the temperature of printhead 22 is within an elevated temperature range of 110° C.-125° C. As shown in Table I, controller 20 uses a minimum programmed delay while the ambient temperature is between 78° F.-85° F. However, as ambient temperature increases, the time rate of cooling decreases and the length of each programmed delay is extended.
For example, where controller 20 receives a print order for the printing of 50 images, and at an ambient temperature of 86° F. (35° C.) and below, the printer controller 20 using the look up table, Table I, can determine a printing pattern that includes a normal 8.5 second print time per image with at least a minimum a programmed delay (e.g. 2.0 seconds) occurring after the printing of a designated number of images, such as five images. It can be anticipated that the temperature at printhead 22 will rise while printing such a volume of images in a sequential manner. However, the pattern of programmed delays that occur does not require any single cool down period to exceed a maximum delay time of 21.5 seconds. Such a pattern provides for generally continuous printing performance of at least fifty images resulting in a total 50 print cycle time of 457 seconds (7 minutes, 37 seconds) or average print time for 50 sequential prints of 9.14 seconds.
Similarly, where the print order comprises an order for the printing of a quantity of 50 images in an environment wherein the ambient temperature is at 96° F. (35° C.), printer controller 20 can refer to Table I and determine that it is possible to maintain continuous printing performance of at least fifty (50) images, allowing for periodic cool downs that result in a total 50 print cycle time of 618 seconds (10 minutes, 18 seconds) or an average print time for 50 sequential prints of 12.36 seconds. This 50 sequential print cycle time allows for a normal 8.5 second print time and with a 21.5 second programmed delay after every fifth print at this elevated temperature. Here too, no single cool down period is to exceed 21.5 seconds.
It will be appreciated that there are many different ways in which look up tables can be used by controller 20. For example, in a particular printer, it may be useful to provide more than one look up table with one look up table being applicable when a printhead 22 is within a first range of temperatures and another look up table being applicable when a printhead 22 is within a second range of temperatures. In another embodiment, a three-dimensional look up table can also be provided to relate printhead temperatures and ambient temperatures with a desired length of a programmed delay.
Controller 20 can determine a printing/programmed delay pattern in advance or portions thereof can be determined during the printing operation. For example, in another embodiment of the invention, the time rate of cooling of printhead 22 can be determined by controller 20 without requiring a second thermal sensor 92. In this embodiment, controller 20 is adapted to provide a programmed delay of the minimum amount of time during periods where printhead 22 is at an elevated temperature and, during the minimum amount of time of the programmed delay, controller 20 determines the time rate of change of the temperature at first thermal sensor 90 by monitoring the first feedback signal to determine the extent of the temperature change that occurs during the minimum programmed delay. Controller 20 then determines a time rate of cooling of printhead 22 based upon the extent of the temperature change at printhead 22 during the minimum programmed delay and from this determines an extent of any desired extended delay.
In another example, controller 20 can be adapted to monitor the temperature of printhead 22 and/or to determine a time rate of cooling of printhead 22 during a minimum portion of a programmed pause and to determine the length of that programmed pause in a manner that allows a next sequence of a designated number of images to be printed without heating printhead 22 to a maximum temperature.
Optionally, instead of the use of a look up table, the length of a programmed delay can be determined based upon a mathematical calculation made by controller 20 based upon the temperature of the printhead and the time rate of cooling or the automatic execution of another functional relationship can be used.
It will be appreciated that controller 20 can be adapted to execute programmed delays in a pattern that is other than one programmed delay after a statically designated number of images has been printed, such as after every fifth print as has been described in the example above. Specifically, controller 20 can designate a programmed delay between each image, after two images, etc. Such a determination can likewise be made based upon the number of images to be printed, the initial temperature of printhead 22 and, optionally, the time rate of cooling of printhead 22. For example, controller 20 can be adapted to execute a programmed delay after a designated number of printed images for large batches of images and to execute a programmed delay after a different designated number of images for smaller batches of images.
Conversely, controller 20 can be optionally adapted to omit execution of an extended programmed delay or to omit execution of a programmed delay entirely where controller 20 determines that the remainder of the print order requires a quantity of images that is less than the designated number of images (step 116), such as in the example above where a print order requests only six or seven images to be printed in the print order. In this way, short batches of images that only modestly extend past a designated number of images can be printed (step 118) without unnecessary programmed delays.
The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.
