High speed parallel printing using meters and intelligent sorting of printed materials

Abstract

A printing system includes an inserter, a buffer, a splitter, and a plurality of media paths each feeding a meter. Another printing system may include an inserter, a buffer, a splitter, a plurality of media paths each feeding a meter, and a system for intelligently recombining the printed materials.

Description

This application claims the benefit of U.S. Provisional Application No. 60/591,392 filed Jul. 27, 2004, and U.S. Provisional Application No. 60/591,394 filed Jul. 27, 2004, which are incorporated by reference herein in their entirety.

BACKGROUND

The present invention relates to a method and apparatus for printing using a plurality of paper paths, each feeding a meter.

BRIEF DESCRIPTION OF RELATED DEVELOPMENTS

Mailing machines enable users to frank one or more mail items by printing a stamp representing the amount paid by the sender. For example, U.S. Pat. Nos. 5,243,908; 5,683,190; 5,526,271; 6,607,095; 6,050,054; 5,293,465; 5,688,729; all of which are incorporated herein by reference in their entirety; disclose franking machines which may comprise franking heads, feeders, folders and user interfaces as examples.

Barcoded indicia generally occupies about 1 square inch, may require 2 pens and 1 printhead to print, and may require a resolution of approximately 300 dots per inch (DPI). Alignment among multiple devices such as pens and printheads can be difficult to achieve and maintain.

Furthermore, the printing devices themselves print at a rate much slower than typical media transport speeds. For example, a typical printhead may be capable of printing 300 DPI on media travelling at a maximum of 55 inches/second. Using envelopes as an example, this translates to approximately 15 thousand envelopes/hour. Typical media transport devices are capable of moving media at much faster speeds.

It would be advantageous to create a system that is capable of printing at speeds faster than presently available. Once material has been printed it would also be advantageous to be able to intelligently sort the printed material.

SUMMARY OF THE EXEMPLARY EMBODIMENTS

In one embodiment, a printing system includes an inserter, a buffer, a splitter, and a plurality of media paths each feeding a meter.

In another embodiment, a printing system includes an inserter, a buffer, a splitter, a plurality of media paths each feeding a meter, and a system for intelligently recombining the printed materials.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features of the present invention are explained in the following description, taken in connection with the accompanying drawings, wherein:

FIG. 1 shows a block diagram of an exemplary embodiment for practicing the features disclosed herein; and

FIG. 2 shows a block diagram of another exemplary embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

Referring to FIG. 1, there is shown, a schematic block diagram of a printing or mailing system 100 suitable for practicing the embodiments disclosed herein and incorporating features in accordance with one exemplary embodiment of the present invention. Although the present invention will be described with reference to the exemplary embodiments shown in the drawings, it should be understood that the present invention can be embodied in many alternate forms of embodiments. In addition, any suitable size, shape or type of elements or materials could be used.

In the exemplary embodiment shown, system 100 may include an inserter 105 for operating on printing media 115. The printing media 115 may for example include mail items. In general, printing system 100 prints upon pieces of printing media 115.

System 100 includes a buffer 110, a splitter 120, and a plurality of media paths 125, 130 feeding a plurality of meters 135, 140. The inserter 105, buffer 110, splitter 120, media paths 125, 130, and meters 135, 140 may be controlled by a processor 145 to maximize throughput.

Processor 145 allocates printing information to each meter 135, 140, and pieces of printing media 115, for example envelopes, are allocated to each meter 135, 140 based on various rules for optimum throughput. The rules may include consideration of media presently in each media path 125, 130, information to be printed, information and media already allocated to each meter, etc. Other rules and considerations may also be used.

Different information may be printed by any of the meters at any given time and each printing media piece 115 may be imprinted with information exclusive to that media piece 115 or may include information common to at least one other media piece 115.

The buffer 110 operates to compensate for differences between the speed of the inserter 105, the splitter 120, the media paths 125, 130, and the meters 135, 140.

The splitter 120 allocates media pieces 115 to each media path 125, 130 according to the rules described above. The splitter 120 may also manage a space or gap between pieces of media 115 in each media path 125, 130.

The processor 145, inserter 105, buffer 110, splitter 120, media paths 125, 130, meters 135, 140 and other components may communicate over a communication path or network 150 and may exchange messages and commands.

Printed media exiting from the meters is generally transported to receptacles 155, 160 at the end of each media path 125, 130, respectively.

FIG. 2 depicts a block diagram of another embodiment, referred to as system 200, for practicing the features described herein.

System 200 includes an inserter 205, a buffer 210, a splitter 215, and a plurality of media paths 220, 225 feeding a plurality of meters 230, 235. The inserter 205, buffer 210, splitter 215, meters 230, 235, and media paths 220, 225 are controlled by a processor 240 to maximize throughput. The inserter introduces printed material 250 into buffer 210. A sorter 245, also controlled by processor 240 is located proximate the ends of the media paths 220, 225 for intelligently recombining, separating, or sorting the printed material 250.

The processor 240 allocates printing information to each meter 230, 235, and the printed material 250, also referred to as pieces of media, for example envelopes, are allocated to each meter 230, 235 by the processor 240 using various rules operated for optimum throughput. The rules may include consideration of media presently in each media path, information to be printed, information and media already allocated to each meter, etc. Other rules and considerations may also be used.

As with the embodiment described above, different information may be printed by any of the meters 230, 235 at any given time. Each media piece 250 may be imprinted with information exclusive to that media piece or may include information common to at least one other media piece.

The buffer 210 operates to compensate for differences between the speed of the inserter 205, the splitter 215, media paths 220, 225, meters 230, 235 and sorter 245.

The splitter 215 allocates media 250 to each media path 220, 225 according to the rules described above. The splitter 215 may also manage a space or gap between pieces of media 250 in each media path 220, 225.

The sorter 245 may communicate with the other components of the system and operates to sort printed materials according to a set of rules that may depend on various parameters associated with the printed material, user input, one or more predetermined criteria, calculated parameters, or any other suitable criteria, parameters, or conditions.

The sorter 245 may combine printed material 250 from one or more of the media paths 220, 225, may operate to separate the printed material 250, may generally sort the printed material 250, or may perform any other operation related to organizing the material 250 delivered by the media paths 220, 225.

The processor 240, inserter 205, buffer 210, splitter 215, media paths 220, 225, meters 230, 235, sorter 245, and other components may communicate over a communication path or network 250 and may exchange messages and commands.

It should be understood that the foregoing description is only illustrative of the invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the invention. One such example is where other configurations of printheads may also be used. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.

Claims

1. A system for printing comprising:

an inserter;

a buffer;

a splitter;

a plurality of media paths; and

a plurality of meters fed by the media paths, wherein the inserter, buffer, splitter, meters, and media paths are controlled to maximize throughput.

2. A printing system comprising:

an inserter;

a buffer;

a splitter;

a plurality of media paths;

a plurality of meters fed by the media paths; and

a sorter located proximate the ends of the media paths for intelligently recombining, separating, or sorting printed material,

wherein the inserter, buffer, splitter, meters, media paths and sorter are controlled to maximize throughput.