US 6,980,767 B1Granted

Method and apparatus for adhering sheets of print media together by use of toner in an electrophotographic printer

AssigneeLexmark International, Inc.

InventorsDaniel P. Cahill, David L. Merrifield

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Abstract

An improved electrophotographic printer is provided for printing on sheet media, and for joining two or more sheets of sheet media together within the print engine. A first sheet can be imaged with “standard” information and/or indicia, and can also have one or more strips of toner applied at predetermined locations. The first sheet is then run back to the print engine while a second (virgin) sheet of print media is picked from an input tray at a time that will cause both sheets to run through the print engine simultaneously, either exactly at the same time, or with some offset spacing. The two sheets will become joined or affixed to one another at locations in which the toner strips are of sufficient size and density, and will be output together as if stapled, or sealed, together.

Claims35

Dependent claims

A method for printing and joining at least two sheets of print media in an image forming apparatus, said method comprising:

(a) providing an image forming apparatus having a print media input device, a print engine that applies and affixes image-forming material to said print media at an image-forming station and at an image-fixing station, a first output pathway that re-directs said print media back to said print engine, and a second output pathway that directs said print media to an output area;
(b) moving a first sheet of said print media from said print media input device to said print engine, and, according to user print data, applying said image-forming material to a first surface of said first sheet at said image-forming station, including to at least one predetermined affixing area of said first surface of the first sheet;
(c) moving said first sheet through said first output pathway, and back to said print engine;
(d) moving a second sheet of said print media from said print media input device to said print engine in a manner such that said second sheet overlaps at least a portion of said first sheet, said portion including said at least one predetermined affixing area, wherein said first surface of the first sheet is facing toward said second sheet;
(e) at said image-fixing station, joining both said first sheet and said second sheet to said image-forming material at said at least one predetermined affixing area, thereby joining said first and second sheets together as combined sheets of print media;
and
(f) thereafter, moving said combined sheets of print media through said second output pathway to said output area.

4 more elements

A method for printing and joining at least three sheets of print media in an image forming apparatus, said method comprising:

(a) providing an image forming apparatus having a print media input device, a print engine that applies and affixes image-forming material to said print media at an image-forming station and at an image-fixing station, a first output pathway that re-directs said print media back to said print engine, and a second output pathway that directs said print media to an output area;
(b) moving a first sheet of said print media from said print media input device to said print engine, and, if called for by user print data, applying said image-forming material to a surface of said first sheet at said image-forming station;
(c) moving said first sheet through said first output pathway, and back to said print engine;
(d) moving a second sheet of said print media from said print media input device to said print engine in a manner such that said second sheet overlaps at least a portion of said first sheet at a first predetermined affixing area, and, if called for by user print data, applying said image-forming material to a surface of said second sheet at said image-forming station;
(e) wherein, said user print data includes applying said image-forming material to at least one of said surfaces of the first and second sheets within said first predetermined affixing area, and at said image-fixing station, joining both said first sheet and said second sheet to said image-forming material at said first predetermined affixing area, thereby joining said first and second sheets together as a first set of combined sheets of print media;
(f) thereafter, moving said first set of combined sheets of print media through said first output pathway and back to said print engine;
(g) moving a third sheet of said print media from said print media input device to said print engine in a manner such that said third sheet overlaps at least a portion of said first set of combined sheets at a second predetermined affixing area, and, if called for by user print data, applying said image-forming material to a surface of said third sheet at said image-forming station;
(h) wherein, said user print data includes applying said image-forming material to at least one of said surfaces of the second and third sheets within said second predetermined affixing area, and at said image-fixing station, joining both said second sheet and said third sheet to said image-forming material at said second predetermined affixing area, thereby joining said second and third sheets together as a second set of combined sheets of print media, which now includes all of said first, second, and third sheets;
and
(i) thereafter, moving said second set of combined sheets of print media through one of:
(i) said first output pathway and back to said print engine, and (ii) said second output pathway to said output area.

8 more elements

A method for printing and joining at least three sheets of print media in an image forming apparatus, said method comprising:

(a) providing an image forming apparatus having a print media input device, a print engine that applies and affixes image-forming material to said print media at an image-forming station and at an image-fixing station, a first output pathway that re-directs said print media back to said print engine, and a second output pathway that directs said print media to an output area;
(b) moving a first sheet of said print media from said print media input device to said print engine, and, if called for by user print data, applying said image-forming material to a surface of said first sheet at said image-forming station;
(c) moving said first sheet through said first output pathway, and back to said print engine;
(d) moving a second sheet of said print media from said print media input device to said print engine in a manner such that said second sheet precedes said first sheet at said print engine and overlaps at least a portion of said first sheet at a first predetermined affixing area, and, if called for by user print data, applying said image-forming material to a surface of said second sheet at said image-forming station;
(e) moving a third sheet of said print media from said print media input device to said print engine in a manner such that said third sheet follows said first sheet at said print engine and overlaps at least a portion of said first sheet at a second predetermined affixing area, and, if called for by user print data, applying said image-forming material to a surface of said third sheet at said image-forming station;
(f) wherein, said user print data includes applying said image-forming material to at least one of said surfaces of the first and second sheets within said first predetermined affixing area, and at said image-fixing station, joining both said first sheet and said second sheet to said image-forming material at said first predetermined affixing area, thereby joining said first and second sheets together as a first set of combined sheets of print media;
(g) wherein, said user print data includes applying said image-forming material to at least one of said surfaces of the first and third sheets within said second predetermined affixing area, and at said image-fixing station, joining both said first sheet and said third sheet to said image-forming material at said second predetermined affixing area, thereby joining said first and third sheets together as a second set of combined sheets of print media, which now includes all of said first, second, and third sheets;
and
(i) thereafter, moving said second set of combined sheets of print media through one of:
(i) said first output pathway and back to said print engine, and (ii) said second output pathway to said output area.

7 more elements

A method for printing and joining two sheets of print media in an image forming apparatus, said method comprising:

(a) providing an image forming apparatus having a print media input device, a print engine that applies and affixes image-forming material to said print media at an image-forming station and at an image-fixing station, a first output pathway that re-directs said print media back to said print engine, and a second output pathway that directs said print media to an output area;
(b) moving a first sheet of said print media from said print media input device to said print engine, and, according to user print data, applying and affixing said image-forming material to a first surface of said first sheet at said image-forming and image-fixing stations, said user print data including a plurality of predetermined security regions;
(c) moving said first sheet through said first output pathway, and back to said print engine;
(d) moving a second sheet of said print media from said print media input device to said print engine in a manner such that said second sheet overlaps at least a portion of said first sheet, wherein said first surface of the first sheet is facing toward said second sheet;
(e) at said image-fixing station, joining both said first sheet and said second sheet to said image-forming material to create security seals at said plurality of predetermined security regions, thereby joining said first and second sheets together as combined sheets of print media;
and
(f) thereafter, moving said combined sheets of print media through said second output pathway to said output area, thereby producing a document having printed information that is sealed from view, without any folding operation and with no separate heated platen apparatus.

4 more elements

An image forming apparatus, comprising:

an interface circuit;
a print media input device, a print engine that applies and affixes image-forming material to said print media at an image-forming station and at an image-fixing station, a first output pathway that re-directs said print media back to said print engine, and a second output pathway that directs said print media to an output area;
wherein:
said interface circuit contains input and output devices that are configured:
(a) to move a first sheet of print media from said print media input device to said print engine, and, according to user print data, to apply said image-forming material to a first surface of said first sheet at said image-forming station, including to at least one predetermined affixing area of said first surface of the first sheet;
(b) to move said first sheet through said first output pathway, and back to said print engine;
(c) to move a second sheet of said print media from said print media input device to said print engine in a manner such that said second sheet overlaps at least a portion of said first sheet, said portion including said at least one predetermined affixing area, wherein said first surface of the first sheet is facing toward said second sheet, and to determine a relative position of a leading edge of said first sheet compared to a leading edge of said second sheet as they move through said print engine;
(d) at said image-fixing station, to join both said first sheet and said second sheet to said image-forming material at said at least one predetermined affixing area, thereby joining said first and second sheets together as combined sheets of print media;
and (e) thereafter, to move said combined sheets of print media through said second output pathway to said output area.

6 more elements

Dependencies are inferred from the claim text.