(12) United States Patent
`Silverbrook
`
`(10) Patent N0.:
`(45) Date of Patent:
`
`US 6,652,052 B2
`Nov. 25, 2003
`
`US006652052B2
`
`(54) PROCESSING OF IMAGES FOR HIGH
`VOLUME PAGEWIDTH PRINTING
`
`6,130,967 A * 10/2000 Lee et al. ................. .. 382/302
`6,229,622 B1 * 5/2001 Takeda .................... .. 358/116
`
`(75) Inventor: Kia Silverbrook, Balmain (AU)
`
`FOREIGN PATENT DOCUMENTS
`
`(73) Assignee: Silverbrook Research Pty Ltd,
`Balmain (AU)
`
`( * ) Notice:
`
`Subject to any disclaimer, the term of this
`patent is extended or adjusted under 35
`U.S.C. 154(b) by 0 days.
`
`EP
`EP
`EP
`JP
`
`540338 B
`899684 A
`940975 A
`404001051 A
`
`1/1998
`3/1999
`9/1999
`1/1992
`
`OTHER PUBLICATIONS
`
`(21) APPL NO_; 10/120,350
`
`(22) Filed:
`
`Apr. 12, 2002
`_
`_
`_
`Prlor Publlcatlon Data
`US 2002/0158924 A1 Oct. 31, 2002
`
`(65)
`
`DerWent Abstract Accession No. 2001—020348/03, T01, JP
`2000—293335 A (Seiko Epson Corporation) Oct. 20, 2000.
`
`DerWent Abstract Accession No. 98—081618/08, JP
`09_314915 A (Canon Kabushiki Kaisha) Dec. 9, 1997.
`
`* cited by examiner
`
`Related US. Application Data
`
`(63) Continuation-in-part of application NO. 09/112,767, ?led on
`Jul. 10, 1998, now Pat. No. 6,416,167.
`Foreign Application Priority Data
`
`(30)
`
`Primary Examiner—stephen D- Meier
`Assistant Examiner—An H. Do
`(57)
`ABSTRACT
`
`Jul. 15, 1997
`
`Mai. 25, 1998
`
`(AU) ............................................ .. PO7991
`
`(AU) ............................................ .. PO2592
`
`(51) Int. Cl.7 ........................ .. B41J 29/38; B41J 29/393
`
`~
`
`~
`
`~
`
`~
`
`~
`
`An image processmg elpparams for a pnnt‘gir mfzludes a PH?“
`engme controller that is con?gured to receive image data in
`an image storage format. The print engine controller
`
`(52) US. Cl. . . . . . . . . . . . . . . . .
`
`. . . . . . . . .. 347/5, 347/19
`
`includes data processing Circuitry that is Con?gured to
`
`(58) Field of Search .......................... .. 347/5, 9, 14,19,
`347/12, 40, 43; 382/302_305; 395/115
`
`(56)
`
`References Cited
`
`U.S. PATENT DOCUMENTS
`
`process the image data at a rate of at least one billion pixels
`per second to transform the data into print data. The print
`engine controller includes data communication circuitry that
`is operatively connected to the data processing circuitry and
`is con?gured to communicate the print data to a printhead.
`
`5,675,719 A * 10/1997 Matias et al. ............. .. 395/115
`
`18 Claims, 14 Drawing Sheets
`
`50
`
`64 M5IT
`45
`256
`254
`DRAM
`IT ————————— --U--—‘-7Z- ------------ --)Z ---- —*| j
`i
`L SDKAM CONTROLLEK H DKAMINTEKFACE UNIT 1
`:
`
`|
`
`i
`11
`i
`PEG
`1
`T“:- CONTKOLLEK
`i
`U 4
`Q
`2 |
`I
`LOW SPEED
`:g
`a :
`INTERFACE
`:c
`1
`1
`‘in
`|
`El
`:
`g |
`L |
`
`220
`
`DATA BUS
`
`ll
`HIGH SPEED
`INTEKFACE
`
`U
`PAGE
`EXf’AN5/0N UNIT
`l
`FINISHEDXXBAND
`
`222
`
`PRINT ENGINE CONTKOLLEK
`A516
`
`)\
`A
`%
`
`g
`E
`
`I
`
`11
`LINE LOADEE /
`FORM/"TEE
`
`_| i
`,
`|
`|
`|
`l
`l
`I
`l
`226 I
`_ b i I
`FRINTHEAD
`'
`INTERFACE <+> LQYNCL
`
`224
`
`'_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __E__A________ _____1
`
`“4
`m
`MI'CKO
`CONTKOLLEK
`
`<
`\L /216 _ y
`MEMJE T
`PKINTHEAD
`
`/41
`
`LOW SPEED 5EKIAL BUS
`
`HP 1013
`Page 1 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 1 0f 14
`
`US 6,652,052 B2
`
`FIG. 1
`
`HP 1013
`Page 2 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 2 0f 14
`
`US 6,652,052 B2
`
`HP 1013
`Page 3 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 3 0f 14
`
`US 6,652,052 B2
`
`56
`
`FIG. 5
`
`HP 1013
`Page 4 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 4 0f 14
`
`US 6,652,052 B2
`
`HP 1013
`Page 5 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 5 0f 14
`
`US 6,652,052 B2
`
`175
`
`FIG. 5
`
`HP 1013
`Page 6 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 6 6f 14
`
`US 6,652,052 B2
`
`HP 1013
`Page 7 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 7 0f 14
`
`US 6,652,052 B2
`
`116 60
`
`25
`102
`10
`704 /
`76
`14
`94
`
`64 40 52
`
`750
`62
`42
`70
`76
`125
`
`'06
`
`142
`
`126
`124
`146
`
`122
`156
`164
`
`F,
`
`0.
`
`114
`
`110
`10136
`116
`
`154
`129
`
`~47
`
`74 g
`
`'
`
`152
`
`120
`772
`
`140
`
`'
`
`4
`
`156
`105
`
`144 O
`
`© ©
`
`145
`
`Q 0
`
`/<5\
`
`162 22
`
`FIG. 7
`
`HP 1013
`Page 8 of 24
`
`

`
`U.S. Patent
`
`Nov. 25,2003
`
`Sheet 8 0f 14
`
`US 6,652,052 B2
`
`HP 1013
`Page 9 of 24
`
`

`
`U.S. Patent
`
`Nov. 25, 2003
`
`Sheet 9 of 14
`
`US 6,652,052 B2
`
`HP 1013
`Page 10 of 24
`
`

`
`U.S. Patent
`
`Nov. 25, 2003
`
`41f001LI.66_.nS
`
`US 6,652,052 B2
`
`
`
`
`
`.5/Smetmflz.3:_\MQ.
`
`
`
`EDS..¢®
`
`3.<MQ
`
`32>mu
`
`muE%:2\Q«Elk29$
`
`,( 4 333:! Va!
`
`E255.OM93.
`
`Q<mI.h2.m.Eumdqmszou
`
`
`
`
`
`mumEmmaEmmaE04
`
`
`
`
`
`wmdowtzoomzfizm.~2QL
`
`\MmQ<Q.~M23MGE
`
`
`
`ammmmIQIumk
`
`Mm.C<V<w.Qk.22:2§m2Exm
`
`
`
`mU<uQmu.2\Mw.\3QMx2QU
`
`Q2<QXXQmI®‘2E
`
`.v.NNNNNammimE04
`
`mu<u.mE2~
`
`ONVQUEHQIN/;/“N34
`
`HP 1013
`Page 11 of 24
`
`

`
`U.S. Patent
`
`Nov. 25, 2003
`
`41f011LI.66hS
`
`US 6,652,052 B2
`
`
`
`.uGE~m:2.SJQQ
`
`manHE
`
`
`
`mmw——MNQQQZNMMQQUMQMMQ<5.EMMQQUMQ
`
`
`
`
`
`dxmzfimmflmmoq5928Em2Q\~2QU
`
`
`
`
`
`M23Bfi.M23Kim..M23m2Q._2QbQ?
`
`N
`
`
`
`
`
`0__u<mm.ut2\mmursmmu$_.m.0:2.wmthsmmuE%:2.mmumsn
`
`
`
`
`
`2952Sea03$
`
`HP 1013
`Page 12 of 24
`
`

`
`U.S. Patent
`
`Nov. 25, 2003
`
`41f021LI.66hS
`
`US 6,652,052 B2
`
`
`
`
`
`
`
`d\_3_mmmmzmmgm2Q...2Q.uNZSZQQ
`
`EMS.VQ
`
`rmsfiwmczI.wm:oE28
`Bmtm:9:0%:
`
`
`
`
`
`MMQQQMQmmexmm-MMQQUMQMmdQMu2©U
`
`ammxm20.‘
`
`m.Q<.¢.Mmk2.
`
`N“GE
`
`.32»m.~Essa:
`
`Q<m..IL..2Ek
`
`QNN
`
`.2m<
`
`
`
`mmdomgzcum262mKZEE
`
`m.._2,.\m.a.fi
`
`SN? 7V/2139 033519/V107
`
`GNVQGEHQ I.-J 00d
`
`HP 1013
`Page 13 of 24
`
`

`
`U.S. Patent
`
`Nov. 25 2003
`
`Sheet 13 0f 14
`
`HP 1013
`Page 14 of 24
`
`

`
`U.S. Patent
`
`Nov. 25 2003
`
`Sheet 14 0f 14
`
`HP 1013
`Page 15 of 24
`
`

`
`US 6,652,052 B2
`
`1
`PROCESSING OF IMAGES FOR HIGH
`VOLUME PAGEWIDTH PRINTING
`
`This is a C-I-P of US. Ser. No. 09/112,767 ?led on Jul.
`10, 1998, now US. Pat. No. 6,416,167.
`
`STATEMENT REGARDING FEDERALLY
`SPONSORED RESEARCH OR DEVELOPMENT
`Not Applicable
`
`FIELD OF THE INVENTION
`This invention relates to the processing of images for high
`volume pageWidth printing. More particularly, this invention
`relates to a method of processing an image for printing, an
`image processing apparatus and an inkjet printer.
`
`REFERENCED PATENT APPLICATIONS
`This application is a continuation-in-part application of
`US. application Ser. No. 09/112,767 now US. Pat. No.
`6,416,167. The folloWimg United States applications and
`patents are hereby incorporated by reference: 6,227,652
`6,213,588 6,213,589, 6,231,163 6,247,795 6,394,581 6,244,
`691 6,257,704 6,416,168 6,220,694 6,257,705 6,247,794
`6,234,610 6,247,793 6,264,306 6,241,342 6,247,792 6,264,
`307 6,254,220 6,234,611 6,302,528 6,283,582 6,239,821
`6,338,547 6,247,796 6,390,603 6,362,843 6,293,653 6,312,
`107 6,227,653 6,324,609 6,238,040 6,188,415 6,227,654
`6,209,989 6,247,791 6,336,710 6,217,153 6,416,167 6,243,
`113 6,583,281 6,247,790 6,260,953 6,267,469 6,273,544
`6,309,048 6,420,196 6,443,558 6,439,689 6,378,989 6,406,
`129 6,505,916 6,457,809 6,457,812 6,428,133 6,362,868,
`6,443,555 09/422,893 09/113,122, noW alloWed 09/425,420,
`noW abandoned 09/693,703, noW alloWed 09/693,727, noW
`abandoned.
`
`BACKGROUND OF THE INVENTION
`High volume, high resolution printing is an objective that
`has been sought by the manufacturers of Wide format
`printers for some time. Wide format printers have been
`available to the public for many years. Examples of popular
`Wide format printers are the HeWlett Packard (HP) 1000/
`5000, the HP 3000/3500, the Epson 7000/10 000 and many
`others.
`These printers all have a traversing printhead that
`traverses a print medium While depositing ink on the
`medium. Applicant believes that these printers suffer from
`inherent disadvantages, particularly When attempts are made
`to utiliZe the design of such printers in order to achieve faster
`printing speeds at high resolutions.
`Central to the problem of achieving high printing speeds
`is the ability to achieve a printhead that is capable of
`generating the necessary number of ink dots at a suitable
`rate. Further, in order to achieve accurate printing, it is
`desirable that a roW or band of the image be created in as
`little print cycles as possible, and preferably in a single print
`cycle. It folloWs that it is undesirable for a traversing
`printhead to be used in an attempt to achieve high print
`speeds and that a single printhead incorporating a suitable
`number of inkjet noZZles is required.
`Thermal printheads also referred to as bubble jet print
`heads and pieZoelectric printheads have been available for
`some time. These suffer from excessive heat build up and
`energy consumption and have therefore been found by the
`applicant to not be suitable for use in a pageWidth con?gu
`ration. A number of disadvantages associated With such
`printheads are set out in US. Pat. No 6,443,555.
`
`10
`
`15
`
`20
`
`25
`
`30
`
`35
`
`55
`
`60
`
`2
`The applicant has developed a printhead chip that is
`capable of producing images having a resolution as high as
`1600 dpi. These chips are manufactured using integrated
`circuit fabrication techniques. Details of the chips are pro
`vided in the above referenced applications and patents.
`Applicant believes that these printhead chips are extremely
`suitable for use in Wide format printers. The reason for this
`is that such chips operate at extremely high speeds due to the
`large number of noZZle arrangements required in a single
`chip and due to the fact that such chips can be driven at an
`extremely high cyclical rate.
`The Applicant has been faced With a number of dif?culties
`in order to achieve the effective use of such printhead chips
`in Wide format printers. One particular difficulty identi?ed
`by the Applicant is the effective control of a number of such
`printhead chips to achieve accurate printing. This control
`must incorporate the use of effective image processing tools
`that are capable of processing stored images at a rate that
`corresponds With the physical rate of printing achievable by
`a number of the above printhead chips.
`
`SUMMARY OF THE INVENTION
`
`According to a ?rst aspect of the invention, there is
`provided a method of processing an image for printing, the
`method comprising the steps of:
`receiving image data in an image storage format;
`transforming the image data into print data at a rate of at
`least one billion pixels per second; and
`communicating the print data to a printhead.
`According to a second aspect of the invention, there is
`provided an image processing apparatus for a printer, the
`image processing apparatus comprising
`a data input means that is con?gured to receive image data
`in an image storage format;
`a data processing means that is operatively connected to
`the data input means and is con?gured to process the
`image data at a rate of at least one billion pixels per
`second to transform the data into print data; and
`a data communication means that is operatively connected
`to the data processing means and is con?gured to
`communicate the print data to a printhead.
`According to a third aspect of the invention, there is
`provided an inkjet printer that comprises
`a support structure;
`a platen positioned in the support structure;
`a print assembly positioned operatively With respect to the
`platen to de?ne a printing Zone betWeen the platen and
`the print assembly, the print assembly comprising
`an elongate carrier; and
`a number of printhead chips positioned on the carrier,
`the printhead chips together de?ning a printhead;
`an image processing apparatus that is operatively
`arranged With respect to the print assembly, the image
`processing apparatus comprising
`a data input means con?gured to receive image data in
`an image storage format;
`a data processing means that is con?gured to process
`the image data at a rate of at least one billion pixels
`per second to transform the data into print data; and
`a data communication means that is con?gured to
`communicate the print data to the printhead; and
`a feed mechanism positioned on the support structure for
`feeding a print medium though the printing Zone.
`The invention is noW described, by Way of example, With
`reference to the accompanying draWings. The folloWing
`
`HP 1013
`Page 16 of 24
`
`

`
`US 6,652,052 B2
`
`3
`description is not intended to limit the broad scope of the
`above summary.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`In the drawings,
`FIG. 1 shoWs a schematic, three-dimensional vieW of part
`of a printing mechanism of a print assembly incorporating
`an image processing apparatus, in accordance With the
`invention, of a printer, also in accordance With the invention;
`FIG. 2 shoWs a front vieW of the printing mechanism of
`FIG. 1;
`FIG. 3 shoWs a rear vieW of the printing mechanism of
`FIG. 1;
`FIG. 4 shoWs a three dimensional, external vieW of the
`printer;
`FIG. 5 shoWs a schematic, three-dimensional vieW of
`operative parts of the printer;
`FIG. 6 shoWs a schematic, exploded vieW of the printer;
`FIG. 7 shoWs a schematic, side sectioned vieW of a
`portion of the printer incorporating the print assembly;
`FIG. 8 shoWs an exploded vieW of an operative portion of
`the printing mechanism;
`FIG. 9 shoWs a cross sectional vieW of an operative
`portion of the printing mechanism;
`FIG. 10 shoWs a high-level block diagram of the image
`processing apparatus;
`FIG. 11 shoWs an expanded block diagram of a page
`expansion unit of the image processing apparatus;
`FIG. 12 shoWs a block diagram of the image processing
`apparatus incorporating the page expansion unit;
`FIG. 13 shoWs a schematic, three-dimensional vieW of
`part of a printhead chip of the print assembly of the printer,
`shoWing one noZZle arrangement of the printhead chip; and
`FIG. 14 shoWs a schematic, three-dimensional vieW of a
`printhead module that incorporates a printhead chip.
`
`DETAILED DESCRIPTION OF THE
`INVENTION
`In FIG. 4, reference numeral 10 generally indicates a
`printer, in accordance With the invention. The printer 10 has
`a support structure 12 that supports a print assembly 14
`above a substrate. The support structure 12 includes a pair of
`spaced feet 16 and a leg 18 extending from each foot 16. The
`print assembly 14 is mounted on the legs 18 to span the legs
`18.
`A media tray 20 is positioned betWeen the legs 18. The
`media tray 20 is con?gured to store suitable print media,
`such as paper 22.
`The paper 22 is fed from a media feed mechanism in the
`form of a media roll 166 through the print assembly 14 and
`on to a take up spool 24. An electronics enclosure 26 is also
`positioned betWeen the legs 18 to enclose various electronic
`components that are described beloW.
`The print assembly 14 includes a lid 28, With a handle 30,
`and a front cover 32. The lid 28 and front cover 32 are
`positioned betWeen a pair of end moldings 34.
`The print assembly 14 also includes a color TFT LCD 36
`With touch screen navigation. A stop button 38 is also
`provided to enable a user to stop operation of the print
`assembly 14.
`The print assembly 14 and its various components are
`shoWn in further detail in the remaining Figures.
`In FIGS. 1 to 3, reference numeral 40 generally indicates
`a printing mechanism of the print assembly 14. As can be
`
`10
`
`15
`
`25
`
`35
`
`45
`
`55
`
`65
`
`4
`seen in the draWings, the printing mechanism 40 is seg
`mented. In particular, the printing mechanism 40 includes an
`image processing apparatus, in accordance With the
`invention, that includes nine printed circuit boards (PCB’s)
`42 connected to each other With corresponding connector
`blocks 44.
`The printing mechanism 40 further includes a printhead
`41 having seventy-tWo printhead modules 46. Each PCB 42
`is con?gured to control eight printhead modules 46. It
`folloWs that nine PCB’s 42 are provided. The printhead
`modules 46 are described in further detail beloW.
`Each PCB 42 includes a print engine controller (PEC) 48.
`The PEC’s 48 are also described in further detail beloW.
`Each PCB 42 also includes a memory storage device in
`the form of memory chips and more particularly in the form
`of 64 Mbit external DRAM chips 50. The DRAM chips 50
`cooperate With the PEC 48 in a manner that is described
`beloW.
`Further, each PCB 42 includes a quality authentication
`(QA) chip 52. Details of a suitable QA chip are set out in the
`above referenced US. Pat. No. 6,362,868 and are therefore
`not set out in this description. The QA chip 52 serves to
`inhibit unauthoriZed re?lling of ink in the manner described
`in US. Pat. No. 6,362,868, in addition to other functions
`such as ensuring the quality of print media used With the
`printer 10.
`An endmost PCB 42 includes a serial connector 54 that
`permits serial data cables 56 to be connected to the PCB’s
`42.
`Each PCB 42 is connected to its associated printhead
`modules 46 With a ?exible PCB 58.
`The printing mechanism 40 includes a metal chassis 60
`that extends betWeen a pair of side moldings 61 that are
`positioned in the end moldings 34. The PCB’s 42 are
`mounted on the chassis 60. The chassis 60 has a generally
`U-shaped cross section. A channel 62 of an Invar alloy is
`positioned on the chassis 60.
`A chassis molding 64 of a plastics material is positioned
`on an outside of the chassis 60 and the channel 62. Each
`PCB 42 is mounted on the chassis molding 64.
`The chassis molding 64 de?nes a pair of recesses 66 on an
`outer side of the chassis molding 64. The recesses 66 extend
`a length of the chassis molding 64. Abusbar 68 is positioned
`in each recess 66. The busbars 68 are con?gured to supply
`electrical poWer to the PCB’s 42.
`An ink reservoir assembly 70 is positioned in the Invar
`channel 62. The ink reservoir assembly 70 includes an ink
`distribution arrangement 72. Each printhead module 46 is
`positioned on a respective ink distribution arrangement 72.
`In particular, each printhead module 46 is removably
`mounted on its ink distribution arrangement 72 to facilitate
`removal and replacement When necessary.
`The ink reservoir assembly 70 includes a plurality of ink
`reservoir moldings 76.
`Each ink reservoir molding 76 corresponds With an asso
`ciated printhead module 46. The ink reservoir moldings 76
`are positioned end-to-end along and Within the Invar channel
`62. Each ink reservoir molding 76 de?nes a plurality of
`elongate ink channels 74, each accommodating a differently
`colored ink. Thus, effective elongate ink channels extend a
`length of the Invar channel 62.
`An end cap molding 78 is positioned on an endmost ink
`reservoir molding 76. The end cap molding 78 has a plurality
`of connectors 80 de?ned thereon and in alignment With
`respective ink channels 74 When the end cap molding 78 is
`
`HP 1013
`Page 17 of 24
`
`

`
`US 6,652,052 B2
`
`10
`
`15
`
`35
`
`45
`
`5
`positioned on said endmost ink reservoir molding 76. The
`connectors 80 are connectable to an ink hose connector 82.
`The ink hose connector 82 is, in turn, connected to each of
`a plurality of ink hoses 84. It folloWs that each hose 84 is in
`?uid communication With a respective ink channel 74. Each
`hose 84 supplies the ink reservoir assembly 70 With ink of
`a particular color. For example, the hoses 84 can carry Cyan
`(C), Magenta (M), YelloW (Y) and Black
`inks, respec
`tively. In this case, four hoses 84 are provided. Also, each
`reservoir molding 76 de?nes four ink channels 74.
`Alternatively, the hoses 84 can carry Cyan (C), Magenta
`(M), YelloW (Y), Red (R), Green (G) and Blue (B) inks,
`respectively. In this case, six hoses 84 are provided. Also,
`each reservoir molding 76 then de?nes six ink channels 74.
`Instead of six differently colored inks, the six hoses 84 can
`carry CMYK and Infrared (IR) inks and a ?xative
`for
`high speed printing so that the inks can dry rapidly.
`Each hose 84 is connected to a respective ink container 86
`(FIG. 5), so that each hose 84 is connected betWeen an ink
`container 86 and a particular ink channel 74. The hoses 84
`are connected to their respective containers 86 With T-piece
`connectors 94 shoWn in FIG. 1.
`The print assembly 14 includes a plurality of capping
`devices 88 that correspond With respective printhead mod
`ules 46. Each capping device 88 is displaceable betWeen an
`operative position in Which it serves to cap its respective
`printhead module 46, to inhibit drying of ink, and an
`inoperative position in Which ink can be ejected from the
`printhead module 46. A camshaft 90 is positioned in the
`chassis 60. A translating member 92 interconnects the cam
`shaft 90 and the capping devices 88, so that rotational
`movement of the camshaft 90 results in reciprocal move
`ment of the capping devices 88 betWeen their operative and
`inoperative positions.
`The camshaft 90 is driven With a suitable motor, indicated
`generally at 96 in FIG. 5.
`Further detail of the print assembly 14 is shoWn in FIG.
`7. As can be seen in this draWing, the front cover 32, the lid
`28 and a rear cover 98 together de?ne a housing 100 for the
`print assembly 14.
`Aplurality of ink cartridges 102 is positioned beneath the
`lid 28. Each ink cartridge 102 stores one of the inks
`mentioned above. Each ink cartridge 102 is positioned
`betWeen a pair of clips 104 so that it can be replaced When
`necessary. Each ink cartridge 102 and a respective ink
`reservoir 86 are in ?uid communication With each other,
`When the ink cartridge 102 is received betWeen the clips 104.
`Apair of platens, in the form of an upper platen 106 and
`a loWer platen 108 is positioned Within the housing 100. A
`pair of spaced primary rollers in the form of an upper
`primary roller 110 and a loWer primary roller 112 is provided
`to displace the paper 22 through the print assembly 14. The
`upper roller 110 is positioned at an upper end of the platens
`106, 108, While the loWer roller 112 is positioned betWeen
`the platens 106, 108. The rollers 110, 112 are con?gured to
`drive a sheet of the paper 22 over, consecutively, an inner
`surface of the loWer platen 108 and an outer surface of the
`upper platen 106. Thus, the paper 22 passes over the upper
`roller 140, While the loWer roller 112 is positioned betWeen
`upWardly and doWnWardly moving portions of the paper 22.
`A brush 114 is pivotally mounted at 116 to the housing
`100. The brush 114 has an arcuate transverse pro?le that
`corresponds With the upper primary roller 110. The brush
`114 20 is positioned in the housing 100 so that the paper 22
`can pass betWeen the brush 114 and the housing 100.
`Apinch roller 118 is positioned doWnstream of the brush
`114 to bear against the upper primary roller 110. Thus, When
`
`55
`
`65
`
`6
`the paper 22 is displaced from betWeen the brush 114 and the
`upper primary roller 110, the pinch roller 118 retains the
`paper 22 against lateral movement.
`The upper platen 106 de?nes an upper printing Zone 120
`and a loWer cutting Zone 122. A gap 124 is de?ned betWeen
`the upper and loWer printing Zones 120, 122. Aplurality of
`spiked Wheels 126 is partially received through the gap 124
`to engage the paper 22 and the loWer primary roller 112. A
`crossbar 128 is operatively positioned With respect to the
`spiked Wheels 126 to retain the spiked Wheels 126 in
`position. The spiked Wheels 126 and the pinch roller 118 are
`con?gured so that a suitable tension is set up in the paper 22
`When the paper 22 passes over the printing Zone 120 of the
`upper platen 106.
`The chassis 60 and channel 62 are positioned above the
`printing Zone 120 of the upper platen 106. The chassis 60
`and the channel 62 are connected to a displacement mecha
`nism 129 so that the chassis 60 and channel 62 can be
`displaced from the printing Zone 120 When necessary. In
`particular, the chassis 60 and channel 62 are displaceable
`betWeen an operative position in Which the printhead mod
`ules 46 are a distance from the printing Zone 120 that is
`suitable for printing and an inoperative position in Which the
`paper 22 can be released from the printing Zone 120.
`The chassis 60 and channel 62 are connected to the pinch
`roller 118 With suitable metalWork 130. Further, the chassis
`60 and channel 62 are connected to the crossbar 128. It
`folloWs that, When the displacement mechanism 129 is
`operated, the pinch roller 118 and the spiked Wheels 126 are
`displaced from the upper platen 106 together With the
`chassis 60 and the channel 62.
`The displacement mechanism 129 includes a camshaft
`132 and a pusher 134. The pusher 134 is connected to the
`chassis 60 and the channel 62 so that, upon rotation of the
`camshaft 132, the chassis 60 and channel 62 are displaced
`toWards and aWay from the printing Zone of the upper platen
`106.
`Upper idler rollers 136 are rotatably mounted above the
`upper platen 106 so that the paper 22 is received betWeen the
`upper platen 106 and the upper idler rollers 136.
`A loWer, sprung idler roller 138 is mounted on the loWer
`platen 108 to be partially received through a gap 140 de?ned
`in the loWer platen 108. The sprung idler roller 138 is
`con?gured and positioned to bear against the loWer primary
`roller 112. Thus, an upWardly moving portion of the paper
`22 is gripped, and passes betWeen, the loWer primary roller
`112 and the sprung idler roller 138.
`The print assembly 14 includes a cutting mechanism 142
`that is mounted in the housing 100 above the cutting Zone
`122 of the upper platen 106. The cutting mechanism
`includes a cutter 146 that traverses the paper 22 to cut the
`paper 22. The cutting mechanism 142 includes an optical
`sensor 144 so that the cutter 146 can be stopped When it
`reaches an end of a cutting stroke. The cutting Zone 122
`de?nes a cutting formation 148 that cooperates With the
`cutter 146 to facilitate cutting of the paper 22.
`As can be seen in FIG. 6, the print assembly 14 includes
`an air impeller 150 and a motor 152 to drive the air impeller
`150. The air impeller 150 serves to generate an air current
`Within the housing 100 for cooling purposes. An air ?lter
`153 is also positioned in the housing 100 to ?lter the air
`passing through the housing 100. The air impeller 150 also
`serves to generate the air current to a sufficient extent to
`minimiZe the build up of dust on the printhead modules 46.
`As can further be seen in FIG. 6, the primary rollers 110,
`112 are connected to a gearbox 154 that is mounted on a
`
`HP 1013
`Page 18 of 24
`
`

`
`US 6,652,052 B2
`
`7
`bracket 156. The gearbox 154 and bracket 156 are posi
`tioned on one of the legs 18 and covered With one of the end
`moldings 34. Thus, the primary rollers 110, 112 serve to
`drive the paper 22 through the print assembly 14.
`Aprinthead bracket 157 is positioned in the housing 100
`and extends betWeen the legs 18. The printhead bracket 157
`provides a support structure for the chassis 60 and channel
`62. The printhead bracket 157 also provides a support
`structure for the upper idler rollers 136.
`The housing 100 is shaped to de?ne an opening 158 for
`passage of the paper 22 into and out of the print assembly 14.
`Feed rollers 162 are rotatably mounted on a tie bar 160 that
`extends betWeen the legs 18. The feed rollers 162 are
`positioned so that the paper 22 passes over the feed rollers
`162 When the paper is fed into the print assembly 14. The tie
`bar 160 also serves a structural purpose in that it provides
`structural rigidity to the printer 10.
`Discharge rollers 164 are rotatably mounted on the upper
`platen 106. The discharge rollers 164 are positioned so that
`the paper 22 passes over the discharge rollers 164 When the
`paper 22 is fed from the print assembly 14.
`Both the media roll 166 and the take up spool 24 are
`driven With a media roll drive motor 168 and a take up spool
`drive motor 170, respectively (FIG. 5).
`The printer 10 includes a poWer supply unit 172 that is
`positioned in the electronics enclosure 26. The poWer supply
`unit 172 is con?gured to be poWered by either a 110V or
`220V poWer supply. Further, the poWer supply unit 172 is
`con?gured so that up to 90 Amps can be draWn from the
`poWer supply unit 172. The poWer supply unit 172 is
`connected With poWer cables 173 to various components of
`the printer 10, such as the various drive motors to supply the
`components With required operational energy.
`The printer 10 includes an ATX motherboard 174 that is
`also positioned in the electronics enclosure 26. Aprinthead
`interface card 176 is mounted on the motherboard 174. The
`printhead interface card 176 is connected to the nine PCB’s
`42 With suitable data cables 178. Thus, conventional print
`data supplied to the interface card 176 from the motherboard
`174 can be converted into a suitable form for reading by the
`various PCB’s 42.
`The printer 10 includes a hard drive unit 180.
`Conveniently, the hard drive unit 180 can have a capacity of
`40 Gigabytes. This facilitates the storage of entire images to
`be printed. The hard drive unit 180 is connected to the
`motherboard 174 in a conventional fashion. The hard drive
`unit 180 is a conventional hard drive unit and is therefore
`capable of storing images in any number of formats, such as
`the Well-knoWn JPEG format. The manner in Which the
`image data is read from the hard drive unit 180 is also
`conventional. As is set out beloW, printing of the images is
`digitally controlled as a result of the printhead technology
`utiliZed in this invention. It folloWs that transferal of image
`data from the hard drive unit 180 to the PCB’s 42, via the
`printhead interface card 176 can take place Without the
`requirement of signi?cant data transformation, in particular,
`Without the requirement of digital to analogue signal con
`version.
`The interface card 176 is also connected to a motor and
`LCD controller PCB 182 to control operation of the various
`drive motors and the TFT LCD. Details of such control are
`set out in the above referenced applications and are therefore
`not provided in this description. The motor and LCD con
`troller PCB 182 is connected to a cut off sWitch 184 that is,
`in turn, connected to the stop button 38 so that operation of
`the printer 10 can be halted.
`
`15
`
`25
`
`35
`
`45
`
`55
`
`65
`
`8
`As can be seen in FIG. 14, the printhead modules 46 each
`include a printhead chip 186. The printhead chip 186 can be
`in the form of any of the printhead chips described in the
`above referenced applications/patents. Each printhead mod
`ule 46 includes a carrier 187 in Which the printhead chip 186
`is positioned. The carrier 187 de?nes a suitable connection
`Zone for the ?exible PCB 58 associated With the printhead
`chip 186. FIG. 13 shoWs a schematic diagram of part of a
`printhead chip 186 that is suitable for use in the printer 10.
`Each printhead module 46 includes What are knoWn as on
`chip ?ducials 258. The on chip ?ducials 258 are essentially
`in the form of markers to facilitate accurate alignment of the
`printhead modules 46 in the print assembly 14.
`The printhead chip 186 is described in detail in the above
`referenced US. Pat. No. 6,416,167 and Will therefore not be
`described in such detail in this speci?cation. Brie?y,
`hoWever, the chip 186 includes a Wafer substrate 188. A
`CMOS drive circuitry layer 190 is positioned on the Wafer
`substrate 188 and is connected to the ?exible PCB 58.
`A plurality of noZZle arrangements 210 is positioned on
`the CMOS drive circuitry layer 190. For the purposes of
`convenience, one such noZZle arrangement 210 is shoWn in
`FIG. 13. The printhead chip 186 comprises a multiple
`replication of the noZZle arrangement 210 on the Wafer
`substrate 188. As set out in the above referenced applications
`and patents, the printhead chip 186 is the product of an
`integrated circuit fabrication technique. Replication of com
`ponents in order to achieve a product is a Well-knoWn feature
`of such a fabrication technique. It folloWs that the printhead
`chip 186 can readily be understood by a person of ordinary
`skill in the ?eld of chip fabrication.
`Each noZZle arrangement 210 includes a thermal bend
`actuator 192 that is positioned on the CMOS layer 190 to
`receive an actuating signal from the CMOS layer 190. In
`particular, the thermal bend actuator 192 includes a support
`post 194 that is mounted on the CMOS layer 190 to extend
`from the CMOS layer 190. The thermal bend actuator 192
`includes an actuator arm 196 that is ?xed to, and extends
`from, the support post 194. The actuator arm 196 includes a
`heating layer 198 in the form of an electrical heating circuit
`of a material having a coef?cient of thermal expansion that
`is such that the material is capable of performing useful
`Work on a MEMS scale as a result of expansion upon
`heating. The heating layer 198 is positioned on a layer 200
`of a material having a coef?cient of thermal expansion that
`is less that that of the heating layer 198 de?ning the
`electrical heating circuit. The heating layer 198 is positioned
`intermediate the layer 200 and the substrate 188 so that the
`actuator arm 196 is bent aWay from the substrate 188 When
`a current is