Media replacement process for thermal printers

Abstract

The present invention embraces a method and apparatus for improving ribbon replacement for thermal printers. The present invention also applies to replacement of other media in associated printers. The improvement is achieved based a ribbon adapter or media adapter that is designed for two conditions: 1) catch condition for printing, and 2) release condition for replacing the media in the printer. By a single click or press of a button, a user can switch between the two conditions. The printing operation occurs during the catch condition. The catch condition ensures that there is no or little relative movement between media core and media adapter. The media adapter can also support different diameter media cores. The release condition is implemented when the user replaces media. The release condition can provide a relatively easy replacement of a media without a significant force or pressure.

Claims

1. A method, comprising steps of: activating a release condition with a press of a button on a media adapter of a printer, wherein the media adapter comprises a push rod, a catcher, and a spring, wherein the catcher comprises a plurality of claws; removing a media core from the media adapter; loading a spool of media on the media adapter; activating a catch condition with another press of the button on the media adapter; and printing utilizing the spool of media, wherein, the push rod comprises wedge structures.

2. The method as in claim 1, wherein, each press of the button of the media adapter causes the media adapter to switch from the catch condition to the release condition, or vice-versa.

3. The method as in claim 1, wherein, the activation of the release condition causes the plurality of claws of the catcher to retract inward.

4. The method as in claim 1, wherein, the activation of the catch condition causes the plurality of claws of the catcher to push outward.

5. The method as in claim 1, wherein, each press of the button on the media adapter causes a forward or backward movement of the button and the push rod and causes a clockwise or counterclockwise rotation of the push rod based on a wedge-shaped force between the button and the push rod.

6. The method as in claim 1, wherein, when the spool of media is depleted from media supply spindle, re-activate release condition.

7. The method as in claim 1, wherein, on a thermal printer, a media takeup spindle is the media adapter.

8. The method as in claim 1, wherein on a thermal printer, a media supply spindle is the media adapter.

9. A media adapter, comprising: a cylindrical button with one or more force points at one end of the cylindrical button; a cylindrical push rod with a plurality of wedge-shaped edges at one end of the cylindrical push rod and a pointed shaped at another end of the cylindrical push rod; a cylindrical catcher comprising a plurality of claws; and a spring positioned inside of the cylindrical catcher, wherein, a press of the cylindrical button causes the plurality of claws of the cylindrical catcher to push outward or to retract inward.

10. The media adapter as in claim 9, wherein, the one or more force points at one end of the cylindrical button are positioned to interface with the plurality of wedge-shaped edges at one end of the cylindrical push rod.

11. The media adapter as in claim 9, wherein, the pointed shaped at the another end of the cylindrical push rod is positioned inside the cylindrical catcher and the spring.

12. The media adapter as in claim 9, wherein, when the plurality of claws of the cylindrical catcher are pushed outward, the plurality of claws catch a surface of a media core to secure a position of the media adapter relative to the media core.

13. The media adapter as in claim 9, wherein, when the plurality of claws of the cylindrical catcher are retracted inward, the plurality of claws release a surface of a media core to allow the media core to be removed from the media adapter.

14. The media adapter as in claim 9, wherein, each press of the cylindrical button causes a forward or backward movement of the cylindrical button and the cylindrical push rod and causes a clockwise or counterclockwise rotation of the cylindrical push rod based on a wedge-shaped force between the one or more force points at one end of the cylindrical button and plurality of wedge-shaped edges at one end of the cylindrical push rod.

15. The media adapter as in claim 9, wherein, each press of the cylindrical button causes the media adapter to switch from a catch condition where the plurality of claws are pushed outward, to a release condition where the plurality of claws are retracted inward, or vice-versa.

16. A printer comprising: a cylindrical button, which is incorporated in a media adapter of the printer, comprises one or more force points at one end of the cylindrical button, wherein, a press of the cylindrical button causes a plurality of claws of a cylindrical catcher to push outward or to retract inward, and wherein, the one or more force points at one end of the cylindrical button are positioned to interface with a plurality of wedge-shaped edges at one end of a cylindrical push rod.

17. The printer as in claim 16, wherein, each press of the cylindrical button causes a forward or backward movement of the cylindrical button and the cylindrical push rod and causes a clockwise or counterclockwise rotation of the cylindrical push rod based on a wedge-shaped force between the one or more force points at one end of the cylindrical button and plurality of wedge-shaped edges at one end of the cylindrical push rod.

18. The printer as in claim 16, wherein, each press of the cylindrical button causes the media adapter to switch from a catch condition where the plurality of claws are pushed outward, to a release condition where the plurality of claws are retracted inward, or vice-versa.

19. The printer as in claim 18, wherein, when the plurality of claws of the cylindrical catcher are pushed outward, the plurality of claws catch a surface of a media core to secure a position of the media adapter relative to the media core.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) FIG. 1A illustrates an internal view of a PM43 thermal printer.

(2) FIG. 1B illustrates an embodiment of a cross sectional view of a ribbon adapter and a ribbon core of a PM43 thermal printer.

(3) FIG. 2A illustrates an exemplary embodiment of a ribbon adapter and its components.

(4) FIG. 2B illustrates an exemplary embodiment of a ribbon core installed in a ribbon adapter.

(5) FIG. 2C illustrates an exemplary embodiment of force points and wedge-shaped edges in a ribbon adapter.

(6) FIG. 3 illustrates an exemplary flowchart of a method to replace a ribbon in a printer via a release and catch procedure.

(7) FIG. 4 illustrates an exemplary embodiment of a ribbon adapter and ribbon core in a release condition.

(8) FIG. 5A illustrates an exemplary embodiment of a ribbon adapter in switch process 1 that activates a “catch” conditions with a button press.

(9) FIG. 5B illustrates an exemplary embodiment of wedge-shaped force as utilized in a ribbon adapter.

(10) FIG. 5C illustrates an exemplary embodiment of inside features of a pipe as utilized in a ribbon adapter.

(11) FIG. 5D illustrates an exemplary embodiment of operational aspects of the inside features of a pipe and a button as utilized in a ribbon adapter.

(12) FIG. 5E illustrates an exemplary embodiment of additional operational aspects of the inside features of a pipe and a push rod as utilized in a ribbon adapter.

(13) FIG. 5F illustrates an exemplary embodiment of additional operational aspects of the inside features of a pipe and a push rod as utilized in a ribbon adapter

(14) FIG. 6 illustrates an exemplary embodiment of a ribbon adapter and ribbon core in a “catch” condition.

(15) FIG. 7 illustrates an exemplary embodiment of a ribbon adapter in switch process 2 that activates a “release” condition from a “catch condition” with a button press.

DETAILED DESCRIPTION

(16) The present invention, as described in this Specification, is based on applications supporting thermal transfer ribbon. However, the present invention is not limited to applications supporting thermal transfer ribbon, but may also be applied to other media including, but not limited to, paper, labels, and tickets. In other words, the present invention applies to replacement of other media in associated printers.

(17) The present invention embraces a method and apparatus for improving ribbon replacement for thermal printers. The improvement is achieved based a ribbon adapter designed for two conditions: 1) catch condition for printing, and 2) release condition for replacing the ribbon in the printer. By a single click or press of a button, a user can switch between the two conditions. The printing operation occurs during the catch condition. The catch condition ensures that there is no or little relative movement between ribbon core and ribbon adapter. The ribbon adapter can also support different diameter ribbon cores. The release condition is implemented when the user replaces the ribbon. The release condition may make it relatively easy to replace the ribbon without a significant force or pressure. Hence, in the present invention, each press of the button of the ribbon adapter causes the ribbon adapter to switch from the catch condition to the release condition, or vice-versa.

(18) A thermal printer can have two ribbon adapters, i.e., one for a ribbon supply (or ribbon supply spindle) and another for a ribbon takeup (or ribbon takeup spindle). The ribbon adapter comprises a combination of wedge and spring structures.

(19) When used as a ribbon supply, the ribbon adapter holds a spool of ribbon that is wrapped around a ribbon core. The ribbon adapter is designed to toggle between the two conditions by pressing a button: Catch condition and Release condition. The ribbon adapter is designed in such a way that when the button is pressed, the claws of a catcher component of the ribbon adapter are pushes outward to firmly hold the ribbon core. The catch condition creates an interference fit between the ribbon adapter and the ribbon core.

(20) When the button is pressed again, the ribbon adapter changes to a release condition, where the push rod moves to original position by the spring so that claws are retracted in to the adapter, thus, creating a clearance fit to make it easier to remove the ribbon core.

(21) In a current printer design, e.g., a Honeywell PM43 thermal printer, the ribbon core and the ribbon adapter are always an interference fit. This means there are always pressures between the ribbon core and ribbon adapter. In the present invention, with a release condition, the ribbon core and ribbon adapter have minimal contact with each other, so the sliding wear condition is minimized. Sliding wear occurs when the two parts have relative motion and when they contact each other creating pressure between the two parts.

(22) FIG. 1A illustrates embodiment 100 of an internal view of a Honeywell PM43 thermal printer and the basic components in ribbon adapter 110. Specifically, ribbon adapter 110 comprises a metal part 106 and a plastic part 108. Two ribbon adapters 110 are utilized in a Honeywell PM43 thermal printer. One is utilized as ribbon takeup 102 and the other is utilized as ribbon supply 104. A ribbon core with a spool of ribbon is installed on the ribbon supply 104. After being used in the printing process, the used ribbon is spooled on a ribbon core installed on the ribbon takeup 102.

(23) FIG. 1B illustrates embodiment 150 of a cross sectional view of a ribbon adapter 151 and a ribbon core 152. Ribbon adapter 151 comprises metal of ribbon adapter 154 that provides an interference fit between ribbon adapter 151 and ribbon core 152. With this interference fit, ribbon core 152 can be securely positioned with ribbon adapter 151. That is, there is essentially no movement between ribbon core 152 and ribbon adapter 151.

(24) Since the ribbon core 152 is installed on ribbon adapter 151 multiple times, reciprocating sliding wear can result for both ribbon core 152 and ribbon adapter 151. This wear condition can cause an imperfect catch to ribbon core 152. Hence, the imperfect catch can affect the synchronism between the ribbon core 152 and the ribbon adapter 151. The printing quality can be negatively impacted. For example, while rotating at the same time, a wear condition can allow ribbon adapter 151 to rotate 360 degrees, but can only allow ribbon core 152 to rotate 350 degrees. The printer may only have a small tolerance (e.g., 2 degrees) to accommodate this issue so poor quality printing can result.

(25) FIG. 2A illustrates an exemplary embodiment of a ribbon adapter 200 and its components. Ribbon adapter 200 can be a cylindrical component comprising pipe 201, button 202, PUSH_ROD 204, spring 206, catcher 208, and claws 210. FIG. 2A includes a view of pipe 201 including other components of ribbon adapter 200. Also illustrated is a view of one end of catcher 208. With a press of button 202, PUSH_ROD 204 is forced into catcher 208, as illustrated by a view of the one end of catcher 208. PUSH_ROD 204 receives a counter force from spring 206, which is positioned inside catcher 208. Depending on the condition status, PUSH_ROD 204 can be positioned in the A direction or B direction. As illustrated pipe 201, button 202 PUSH_ROD 204, spring 206, and catcher 208 are cylindrical components. PUSH_ROD 204, spring 206, catcher 208, and claws 210 are located inside of pipe 201. Button 202 comprises plurality of force points 211 at one end of button 202. PUSH_ROD 204 comprises a plurality of wedge-shaped edges 213 at one end of the PUSH_ROD 204 and a pointed shape at the other end of PUSH_ROD 204. Force points 211 are located on corresponding ends of button 202 and wedge-shaped edges 213 are located on one end of PUSH_ROD 204. In other words, when a press of button 202 generates a force between a corresponding end of button 202 and PUSH_ROD 204, the result is referred to as a wedge-shaped force. A wedge-shaped force includes force points 211 which are located on corresponding end of button and wedge-shaped edges which are at the end of the cylindrical PUSH_ROD 204. See additional details on a wedge-shaped force in FIG. 5B and its associated description.

(26) Catcher 208 comprising a plurality of claws 210 depending on the application. The pointed shape at the other end of the PUSH_ROD 204 is positioned inside the catcher and the spring as illustrated in FIG. 2A.

(27) FIG. 2B illustrates an exemplary embodiment 250 of a cross-sectional view of ribbon core 212 installed on a ribbon adapter 216 (also shown in a cross-sectional view). Also shown are cross-sectional-views of button 202, PUSH_ROD 204, spring 206 and catcher 208. As illustrated, ribbon adapter 216 is installed inside ribbon core 212. Both components can be cylindrical components. The space between the outer edge of the ribbon adapter 216 (which is also the outer edge of pipe 201) and the inner edge of ribbon core 212 is gap 214. Depending on the condition status, gap 214 can be an interference fit (catch condition) or a clearance fit (release condition). As noted in FIG. 2B, the components inside of the ribbon core 212 define the ribbon adapter 216. Also, the components in the ribbon adapter 216 are equivalent to the components in ribbon adapter 200 of FIG. 2A.

(28) FIG. 2C illustrates exemplary embodiments 270 and 280 of force points 211 and wedge-shaped edges 213 of ribbon adapter 200 as shown on FIG. 2A. Embodiment 270 shows close-up views of the locations of force points 211 and wedge-shaped edges 213. Arrow 272 shows a shaped corner representing a force point 211 that is located on the end of button 202. Arrow 274 shows a surface representing wedge-shaped edges 213 that are located on the end of PUSH_ROD 204. Embodiment 280 shows the locations of force points 211 and wedge-shaped edges 213 on ribbon adapter 200. Force points 211 are located at the end of button 202, and wedge-shaped edges 213 are located at the end of PUSH_ROD 204.

(29) FIG. 3 illustrates an exemplary flowchart 300 of a method to replace a ribbon in a printer via a release and catch procedure. The method comprises the steps described below. In these steps, references are made relative to the components of FIGS. 2A and 2B.

(30) Release condition: Remove ribbon core 212. Insert or load a new spool of ribbon on ribbon core 212 onto ribbon adapter 216. Ribbon adapter 216 can be ribbon supply 104 (step 302)

(31) Switch Process 1: In order to secure the ribbon core 212 in the ribbon adapter 216, activate catch condition with a press on button 202. (step 304)

(32) Catch condition: Secure a new spool of ribbon on ribbon core 212 in ribbon adapter 216. (step 306)

(33) Print utilizing the new spool of ribbon on ribbon core 212. (step 307)

(34) Switch process 2: When the spool of ribbon is empty or depleted of ribbon, activate release condition with a press of button 202. (step 308)

(35) Repeat step 302-307 to replace the ribbon core 212 and print.

(36) The ribbon adapter 216 can be used as a ribbon takeup 102 to cycle between a release condition and a catch.

(37) FIG. 4 illustrates an exemplary embodiment 400 of cross-sectional views of a ribbon adapter 416 and ribbon core 412 in release condition. Also shown are cross-sectional-views of button 402, PUSH_ROD 404, spring 406, catcher 408, and claws 410. The components inside of the Ribbon Core 412 define the Ribbon Adapter 416. These components include button 402, PUSH_ROD 404, spring 406, catcher 408, and claws 410. The space between the outer edge of the ribbon adapter 416 (which is also the outer edge of pipe 401) and the inner edge of ribbon core 412 is gap 414 (clearance fit).

(38) As illustrated in FIG. 4, the PUSH_ROD 404 is positioned in the direction A, and the Claws 410 are positioned inside the pipe 401. (The number of the claws can be identified based on the application). This means the ribbon core 412 is not caught by ribbon adapter 416 and there is little strength or friction between them. As illustrated, gap 414 has a clearance fit indicating there is adequate space for ribbon adapter 416 to slide in or out of ribbon core 412. User can remove the ribbon core 412 from the ribbon adapter 416 or install the ribbon core 412 with only a little strength or effort because of the clearance fit between these two components. There is little sliding wear between ribbon adapter 416 and ribbon core 412. Thus, users can be conveniently and easily replace the ribbon core 412.

(39) In summary, when claws 410 of catcher 408 are retracted inward, claws 410 release the surface of ribbon core 412 to allow the ribbon core 412 to be removed from the ribbon adapter 416 with little sliding friction.

(40) FIG. 5A illustrates an exemplary embodiment 500 of a ribbon adapter 520 in switch process 1 that activates a “catch” condition from a “release” condition with a button press. Ribbon adapter 520 includes pipe 501, button 502, PUSH_ROD 504, spring 506, and claws 510. Several of these elements are shown in FIG. 5A.

(41) The steps of switch process 1 include: 1) Press Button 502 in Direction B. 2) Button 502 pushes the PUSH_ROD 504 in Direction B. Because of wedge-shape force, PUSH_ROD 504 rotates in a clockwise or counterclockwise direction dependent on the wedge-shaped force between the button 502 and the PUSH_ROD 504. When the PUSH_ROD 504 reaches the position illustrated in pic 1, the PUSH_ROD 504 is not limited by the pipe 501 surfaces, so PUSH_ROD 504 can rotate. 3) Spring 506's force causes PUSH_ROD 504 to move in Direction A while rotating. Rotation is stopped by the surfaces which are inside of the pipe 501 as illustrated in pic 2—catch condition.

(42) FIG. 5B illustrates an exemplary embodiment 530 and embodiment 540 of wedge-shaped force as utilized in a ribbon adapter. As illustrated in exemplary embodiment 530, a wedge-shaped force is a force point that exerts a force upon a wedge-shape. The process for triangle 544 of exemplary embodiment 530 is described below:

(43) 1.1 The triangle 542 gets Force A, then comes in contact with the triangle 544. The connect point is the force point for both the two parts. For the triangle 544, perpendicular to the wedge-shape, there is a Force T. Per embodiment 540, button 502's end is the force point (or points) and Push_Rod 504's end is wedge-shaped.

(44) 1.2 Force T comprises Force R and Force F. In the present invention, one can determine these two directions as pic direction of the arrow.

(45) 1.3 Force F guides the triangle 544 to move in the F direction. The triangle 544 moves to the +F or −F based on whether the Force F is positive or negative (e.g. In FIG. 2B, direction A and direction B). Per embodiment 540, when the pressure, applied by a finger to button 502, is larger than pressure provided by spring 506, PUSH_ROD 504 moves in direction B. Or vice-versa.

(46) 1.4 Force R guides the triangle 544 to move in the R direction. The triangle 544 move to the +R or −R based on whether the Force R is positive or negative. (e.g. rotate clockwise or counterclockwise) Per embodiment 540, rotate clockwise or counterclockwise until the surfaces of PUSH_ROD 504 meet the surfaces of pipe 501, then PUSH_ROD 504 will be stopped.

(47) On the other hand, the process for triangle 542 is described below:

(48) 2.1 When the triangle 544 receives Force T, the triangle 542 receives a counterforce, Force T′.

(49) 2.2 Force T′ comprises Force R′ and Force F′. In the present invention, one can determine these two directions as pic direction of the arrow.

(50) 2.3 Force F′ guides the triangle 544 to move in the F′ direction. The triangle 544 moves to the +F′ or −F′ based on whether the Force F′ is positive or negative (e.g. in FIG. 2B, direction A and direction B). Per embodiment 540, when the pressure, applied by a finger to button 502, is larger than pressure provided by spring 506, PUSH_ROD 504 moves in direction B. Or vice-versa.

(51) 2.4 Force R′ guides the triangle 544 to move in the R′ direction. The triangle 544 moves to the +R′ or −R′ based on whether the Force R′ is positive or negative (e.g. in the present invention, rotate clockwise or counterclockwise). Per embodiment 540, because the surfaces of button 502 always meet the surfaces of pipe 501, button 502 cannot rotate.

(52) Embodiment 540 illustrates the wedge-shaped action between button 502 and PUSH_ROD 504. Each press of button 502 on the ribbon adapter 520 causes a forward or backward movement of button 502 and PUSH_ROD 504 (Direction B and A). Also, when there is a press of button 502, causing Force A to be applied to PUSH_ROD 504, PUSH_ROD 504 rotates clockwise or counterclockwise because of the wedge-shaped power. In other words, each press of the button 502 on the ribbon adapter 520 causes a clockwise or counterclockwise rotation based on a wedge-shaped force between the button and the push rod. Each press of the cylindrical button also causes the forward or backward movement of button 202 and PUSH_ROD 504 (Direction B and A). The wedge-shaped force is a force point that exerts a force upon a wedge-shape. Button 552's end is the force point (or points) and PUSH_ROD 504's end comprises wedge-shapes. In other words, the one or more force points at one end of the cylindrical button are positioned to interface with the plurality of wedge-shaped edges at one end of the cylindrical PUSH_ROD 504.

(53) FIG. 5C illustrates an exemplary embodiment 550 of inside features of a pipe 501 as utilized in a ribbon adapter 520. FIG. 5D illustrates an exemplary embodiment 560 of aspects of the inside features of a pipe 501 including button 502 as utilized in a ribbon adapter 520. When the button 502 moves in direction A, button 502 maybe be stopped when it meets the pipe 501 surfaces which are inside of the pipe 501. FIG. 5E illustrates an exemplary embodiment 570 of additional operational aspects of the inside features of a pipe 501 and PUSH_ROD 504 as utilized in a ribbon adapter 520. FIG. 5F illustrates an exemplary embodiment 580 of additional operational aspects of the inside features of a pipe 501 and PUSH_ROD 504 as utilized in a ribbon adapter 520.

(54) FIG. 6 illustrates an exemplary embodiment 600 of cross-sectional views of a ribbon adapter 616 and ribbon core 612 in a catch condition. Also shown are cross-sectional-views of button 602, PUSH_ROD 604, spring 606, catcher 608, and claws 610. The components inside of the ribbon core 612 define the ribbon adapter 616. These components include button 602, PUSH_ROD 604, spring 606, catcher 608, and claws 610. The space between the outer edge of the ribbon adapter 416 (which is also the outer edge of pipe 601) and the inner edge of ribbon core 612 is gap 614.

(55) As illustrated, the PUSH_ROD 604 is positioned in direction B and the slope of PUSH_ROD 604 pushes the claws 610 outward. This action causes an interference fit between ribbon adapter 616 and ribbon core 612, such that the ribbon core 612 is caught by ribbon adapter 616 very tightly. As there is no more sliding wear to the ribbon adapter 616, the ribbon adapter 616 can maintain its original design strength when catching the ribbon core 612 during printing. The ribbon adapter 616 can also support different diameter Ribbon Cores (0.5″, 1″ . . . ).

(56) In summary, when claws 610 of catcher 608 are pushed outward, claws 610 catch a surface of a ribbon core 612 to secure the position of the ribbon adapter 616 relative to ribbon core 612.

(57) FIG. 7 illustrates an exemplary embodiment 700 of a ribbon adapter 720 in switch process 2 that activates a “release condition from a “catch condition with a button press. Ribbon adapter 720 includes pipe 701, button 702, PUSH_ROD 704, spring 706, and claws 710. Several of these elements are shown in FIG. 7.

(58) Switch process 2 can be implemented with the following steps: 1) Press Button 702 in Direction B. This action can be a single-click of button 702. 2) Button 702 pushes the PUSH_ROD 704 in Direction B. Because of wedge-shape force, PUSH_ROD 704 rotates in a clockwise or counterclockwise direction dependent on the wedge-shaped force between the button 702 and the PUSH_ROD 704. When the PUSH_ROD 704 reaches the position illustrated in pic 3, the PUSH_ROD 704 is not limited by of pipe 701 surfaces, so PUSH_ROD 704 can rotate. 3) Spring 706's force causes PUSH_ROD 704 to move in Direction A while rotating. Rotation is stopped by the surfaces which are inside of pipe 701 as illustrated in pic 4, but PUSH_ROD 704 continues to move in Direction A. When PUSH_ROD 704 meets the pipe's corner, PUSH_ROD 704 stops moving in Direction A as illustrated in pic 5—release condition.

(59) Thermal transfer printing is a digital printing process by melting a coating of ribbon so that it stays glued to the material on which the print is applied. It contrasts with direct thermal printing where no ribbon is present in the process.

(60) To supplement the present disclosure, this application incorporates entirely by reference the following commonly assigned patents, patent application publications, and patent applications:

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(62) In the specification and/or figures, typical embodiments of the invention have been disclosed. The present invention is not limited to such exemplary embodiments. The use of the term “and/or” includes any and all combinations of one or more of the associated listed items. The figures are schematic representations and so are not necessarily drawn to scale. Unless otherwise noted, specific terms have been used in a generic and descriptive sense and not for purposes of limitation.