HK1214211B - Network printer system - Google Patents

Abstract

Electronic systems, such as printing systems, often use components that have integral memory. The integral memory can be used to store information about the component. In some printing systems this memory includes a portion that stores a value indicative of a print yield. Disclosed is a method and system for allowing the memory to have data indicative of an increased print yield.

Description

Network printer system

Priority

This application claims priority from U.S. patent application No.13/667,238 entitled "Network PrinterSystem" filed on day 11/2 2012 by the inventor hereof, the contents of which are incorporated herein by reference in their entirety.

Background

Image recording media such as laser printers use replaceable ink cartridges containing recording materials to record images on the recording media.

Electrostatic or laser printers form images on recording media by transferring toner particles to the media. Generally, a recording drum is charged, and a latent image is formed on the drum by laser light. The latent image is developed on a drum by a developer or toner particles, and the image is transferred directly or indirectly to a recording medium. In a color printer, a plurality of ink cartridges are provided to transfer a color image.

Print cartridges often include memory devices. Such a memory device may be loaded with information indicative of cartridge parameters. When the printer detects that a new ink cartridge has been installed, the printer reads the information from the memory device. This information can be used to calibrate the operation of the printing device based on the cartridge parameters. Typically, the memory device includes information relating to the capacity of the ink cartridge. The printer may read the ink cartridge capacity and print a status page informing the user of information about the ink cartridge. The status page may include information such as the date of manufacture, the type of cartridge, and the estimated page count of the cartridge.

The information stored in the memory may also be used to monitor the print life of the ink cartridge. One method of monitoring the usage of the print cartridges is to count the number of prints performed. In electrostatic printers, a counter may count the number of pixels, lines, or pages printed by each cartridge. Then, each of the counted numbers is processed as a count signal, and the printer sends each of these count signals to an appropriate ink cartridge. The ink cartridge includes a memory that stores an initial value indicating the number of printing agents contained in the ink cartridge. The printer uses the initial value and the number of pages or lines to be printed to determine the remaining life of the cartridge. When the ink cartridge reaches a low level, the printer may alert the operator to replace the ink cartridge and ultimately prevent use of the ink cartridge.

The print cartridges used contain many parts that have a useful life after first use. It is desirable to refill or reproduce these used print cartridges. This provides a less expensive alternative to purchasing a new print cartridge and reduces waste. When refilling a print cartridge, it is advantageous to provide a cartridge with an increased print life. In an inkjet printer, print life can be increased by adding more ink than the ink cartridge is initially filled with or by using an ink with higher printing efficiency. In laser printers, the print life may be extended by filling the cartridge with additional toner or by using toner with improved printing efficiency.

When it is necessary to provide a higher-throughput ink cartridge, it is necessary to change the initial value stored in the memory. If the cartridge has recording capability and an increased number of pages and the initial value indicated by the printer does not reflect the increased capability, the printer can prevent the cartridge from achieving its full print life. Also, if the information stored in memory does indicate increased print capacity, status page printing will not reflect the correct page count.

Image recording devices are also often connected to one or more devices via a network. In an environment such as an office building, it is common to have a plurality of image recording apparatuses of various types connected to a network. It is desirable for the network to manage these printers to ensure that printing is performed by the most appropriate or economical printing device.

There is a third provider to manage these networks of image forming apparatuses. These third parties, often referred to as management print service providers (MPS), manage and maintain the network of the image forming apparatus. The MPS provider monitors the printing network and provides for replacement of the print cartridges and possible maintenance of the printer. The MPS provider charges the user on a page print basis.

MPS providers are expected to use recycled print cartridges to reduce cost and environmental impact. Also, MPS providers are expected to use high-throughput print cartridges because this reduces the frequency of cartridge replacement and cartridge refilling. However, it is important that MSP providers accurately predict end-of-life in high-throughput printing cartridges.

It is therefore an object of the present invention to provide a high-throughput printing cartridge that displays correct information about status pages and prints until the cartridge is free or nearly free of recording material.

Disclosure of Invention

The present methods and systems allow refilling of print cartridges to provide a different throughput than the initial throughput of the print cartridges. For example, a refill print cartridge may be a high-throughput print cartridge that is capable of printing more sheets than a standard-throughput print cartridge. The high-throughput print cartridge can be used in a network printing device.

In one aspect of the application, the method includes refilling a toner cartridge having a waste bin, a hopper, and a cartridge chip including a memory storing information indicative of an initial amount of toner loaded in the toner cartridge, wherein a size of the waste bin limits a maximum amount of toner that can be loaded into the hopper. The method includes determining a toner capacity of a waste bin, determining a coverage efficiency of toner in a hopper to be loaded, and determining a maximum amount of toner that the hopper can be loaded with, wherein the maximum amount of toner is determined based on the toner capacity of the waste bin and the coverage efficiency of toner. The hopper is loaded with a new amount of toner that is greater than the amount of toner originally loaded in the hopper by the original manufacturer. A replacement cartridge chip is provided and includes a memory containing information indicative of a new toner amount or a new page yield.

In another aspect, the method includes refilling a toner cartridge having a waste bin, a hopper, and a cartridge chip that includes a memory that stores information indicative of an initial amount of toner loaded in the toner cartridge, wherein a size of the waste bin limits a maximum amount of toner that can be loaded into the hopper. The method includes determining a toner capacity of a waste bin, selecting toner to be loaded into a hopper, wherein the selected toner has a predetermined coverage efficiency, and determining a maximum amount of toner that the hopper can be loaded with, wherein the maximum amount of toner is determined based on the toner capacity of the waste bin and the coverage efficiency of the toner. The hopper is loaded with a new amount of toner that is greater than the amount of toner originally loaded in the hopper by the original manufacturer. A replacement cartridge chip having a memory containing information indicating a new page yield or a new toner amount is provided on the toner cartridge.

In another aspect, the method includes refilling a toner cartridge having a waste bin, a hopper, and a cartridge chip. The method includes providing replacement toner having one or more characteristics and filling a hopper with a quantity of replacement toner. The cartridge life is determined based on the amount of replacement toner and the toner characteristics. Information indicating the initial amount of toner loaded is updated in the cartridge chip memory based on the determined cartridge life.

In one aspect of the present application, a toner cartridge is for use in an image forming apparatus. The toner cartridge includes a waste bin having a toner capacity, a hopper having a toner capacity, and a cartridge chip. The hopper is initially loaded with toner having a coverage efficiency and the cartridge chip has a memory for storing information indicative of the amount of toner loaded in the hopper. The hopper has a greater toner capacity than the waste bin and is loaded with an amount of toner based on the capacity of the waste bin and the toner coverage efficiency.

In another aspect, the refilled toner cartridge is for use in an image forming apparatus. The refilled toner cartridge has a waste bin with a toner capacity, a hopper with a toner capacity, and a memory having information for storing information indicative of an initial amount loaded in the hopper. The hopper is loaded with a quantity of replacement toner having at least one characteristic different from a characteristic of toner initially loaded in the toner cartridge. Changing the information indicating the initial toner amount based on the at least one characteristic of the replacement toner.

In another embodiment, the "cartridge" is not a print cartridge but another element in the printer that has a limited usage amount (fine aggregate use). For example, printers use rollers to feed the recording medium through the print zone. These rollers may operate by using friction to force the recording medium through the printer. The surface of the roller is often a plastic or rubber-like material that wears out over the life of the printer.

In another aspect of the invention, a system for determining an accurate amount of consumable in a print cartridge is disclosed. The system includes a printing device having a print cartridge loaded therein. The print cartridge has a cartridge identification associated therewith. The system further includes a processor and a peripheral device between the at least one printing device and the processor to monitor communication between the processor and the printing device, wherein the peripheral device determines the precise amount of remaining consumable material by monitoring communication between the processor and the printing device.

In another aspect of the invention, a system for determining an accurate amount of consumable in a print cartridge is disclosed. The system includes a printing device having a print cartridge loaded therein. The print cartridge has a cartridge identification associated therewith. The system further includes a processor. The processor includes software and monitors communication between the processor and the printing device. The processor determines an accurate remaining consumable quantity by monitoring communication between the processor and the printing device based on the cartridge identification.

In another aspect of the invention, the presence of the identification informs the virtual printer or MPS system that a cartridge with a customized production volume is in use and allows the MPS to properly report the toner level and properly interpret when the cartridge will go "low" (go out) and when it will run "out" (go out). The presence of this flag enables the MPS system to more accurately determine the amount of toner remaining to avoid premature cartridge replacement.

The presence of the identification enables the MPS system to determine that the cartridge was reproduced by a certain company. In addition, the presence of this identification enables the MPS system to determine that the cartridge should preferably be recycled or returned by a certain company, with information and a phone number of the remanufacturer.

The presence of the identification may enable the MPS system to change printer messages, LCDs, warning lights, etc., that the printer may present to the printer operator. Further, the presence of this identification enables the MPS system to undo (override) the information that users sending print jobs will receive on their computers.

The system and method also allow the MPS system to reject print jobs, retain printer status information, route printer jobs to specific printers, and enable a user to print only on specific printers.

The system and method also enable the MPS system to reset the printer, at some point in the life of the cartridge, (or request user intervention to reset the printer), thus identifying that some parameters can be adjusted to reflect their correct production information.

The system and method also enable the MPS system to affect other printer status displays, such as the supply status page, the printer internal web server, and the printer tool software.

These and other structures and objects of the present invention will be more fully understood from the following detailed description of the embodiments, which should be read in light of the accompanying drawings.

In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.

As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.

Drawings

The accompanying drawings, which are incorporated in and form a part of the specification, illustrate embodiments of the present invention and, together with the description, serve to explain the principles of the invention:

FIG. 1 illustrates a perspective view of a drive side end of a prior art toner cartridge;

FIG. 2 illustrates a perspective view of a non-drive side end view of a prior art toner cartridge;

FIG. 3 illustrates a perspective view of a scrap bin assembly;

FIG. 4 illustrates a perspective view of a scrap bin assembly;

FIG. 5 illustrates a cross-sectional view of a chip holding structure of a prior art toner cartridge;

FIG. 6 illustrates a method of filling a toner cartridge;

FIG. 7 illustrates another method of filling a toner cartridge;

FIG. 8a illustrates a toner cartridge with a standard hopper, and FIG. 8b illustrates a toner cartridge with an expanded throughput hopper;

FIG. 9 illustrates a conventional managed printing system;

FIG. 10 illustrates a system for monitoring a printing device;

fig. 11 illustrates data stored in the cartridge chip.

Detailed Description

In an imaging and printing apparatus, the page count recorded by a non-volatile memory module ("memory module") may be incremented as pages are printed. The page count may include a total number of pages printed by the printer and a total number of pages printed by each of the plurality of print categories. Recording the number of pages of an individual print category allows recording the page count for a particular type of print job, such as total color pages, monochrome pages, letter size pages, legal size pages, transparency, etc. that can be printed. In addition to recording page counts, the non-volatile memory module may be packaged with a reservoir, such as an ink or toner cartridge, and the memory module may contain one or more fields for recording depletion of the reservoir. One of ordinary skill in the art will appreciate that the imaging and printing apparatus may include non-volatile memory modules having one or more counts, resource bit fields, or a combination thereof.

Fig. 1 and 2 show perspective views of a prior art toner cartridge 100. Toner cartridge 100 includes, among other components, a toner hopper assembly 102 and a waste bin assembly 104. Fig. 3 and 4 show perspective views of the waste bin assembly 104 after separation from the toner cartridge 100. The waste bin assembly 104 includes a waste bin 106, an Organic Photoconductor (OPC) drum 108, and a chip holding structure 140, which are described in more detail below. The OPC drum 108 comprises a cylindrical tube having first and second hubs 110 and 112 with each hub 110 and 112 extending from an end of the OPC drum 108. The OPC drum 108 is held in place by a drive side end cap 114 and a non-drive side end cap 116, which drive side end cap 114 and non-drive side end cap 116 include retaining members 118 and 120, respectively. The OPC retaining members 118 and 120 each include cylindrical openings that engage and occupy the ends of the hubs 110 and 112 during rotation of the OPC drum 108. The cylindrical opening of the OPC retaining member 120 is narrowed at the ends by flanges 122.

FIG. 5 shows a cross-sectional view of a chip holding structure 500 of a prior art toner cartridge holding an OEM chip 502. The OEM chip 502 may include electrical contacts 504 on one side of a Printed Circuit Board (PCB)506 for interfacing with a printer, and circuitry 508 including memory cells on the opposite side. The plastic flanges 510 and 512 hold the OEM chip from the top and sides, while the support member 514 supports the bottom of the chip 502. The support member 514 and flanges 510 and 512 form a slot into which the chip 502 is inserted for attachment to a toner cartridge.

The OEM chip 502 includes a memory element that stores data related to the toner cartridge. The data may include the manufacturer date, manufacturer name, cartridge parameters, toner type, toner amount, and any other desired information. When the cartridge is initially inserted into the printer, the printer communicates electronically with the chip. The communication may be used to verify that the cartridge is the correct cartridge, i.e., a cartridge produced by the OEM and designed to work with a particular printer. The printer may also read data from memory indicating toner parameters, including toner load. The printer then calculates the expected page life of the cartridge, i.e., the number of pages that the cartridge should be able to record if the toner runs out. The printer may print a status page indicating whether the cartridge is authorized for use and the expected page life of the cartridge.

The printer also uses the data in the memory to determine the amount of toner remaining in the cartridge. The printer includes a counter that counts the number of recorded sheets or the number of recorded pixels. When the number of sheets recorded approaches the expected page life of the cartridge, the printer indicates that the toner is low. The printer may finally determine that the cartridge should be empty of toner and disable printing. Alternatively, the printer may include a toner, a sensor, a light pipe, or some other mechanism for determining the actual level of toner remaining in the toner cartridge. The toner detector may be activated when the toner count approaches the expected page life of the cartridge.

Although a toner cartridge has been described, the above case is applicable to any type of printer. For example, inkjet printers have ink cartridges that include an integral ink tank or ink cartridges that are connected to a separate ink tank. The ink cartridge (or separate ink tank) includes a memory that stores information such as the type of ink, printer validation data, and the amount of ink. This information is used to authenticate the ink cartridge and to determine the print capacity of the ink cartridge.

Often, OEMs do not always fill the print cartridges with the maximum amount of recording material that the cartridges can occupy. For example, in toner cartridges, the capacity of the waste bin is often lower than the capacity of the hopper. To ensure that the scrap bin does not overflow, the OEM fill hopper is below capacity.

It is desirable to refill or remanufacture used print cartridges. The refilled print cartridge provides a more affordable replacement cartridge. While maintaining print quality and reducing waste. The printing capacity of a refilled print cartridge can often be increased. Page capacity can be increased by filling the print cartridge with more recording material (e.g., ink or toner) than the cartridge was originally filled with.

Another way to increase the print capacity of a print cartridge is to use a more efficient recording material that can be used that allows the same amount of recording material to record additional pages. For example, toner has an efficiency rating that describes how much toner is used to record an image. The higher the level of efficiency, the more images the toner has that can be recorded using black powder. Also, the higher the grade, the less wasted toner is captured in the waste bin. In one embodiment, the toner cartridge is loaded with toner having an efficiency of 75% or greater. In another embodiment, the cartridge is loaded with toner having an efficiency of 85% or greater. Conversely, if the print cartridge is filled with a recording material that is less efficient than the original toner, the print cartridge will have a reduced yield.

Another way to increase the printing throughput of a print cartridge is to enlarge the components of the print cartridge. For example, in a toner cartridge, the size of the waste bin may be increased to allow the waste bin to hold more toner. In any type of printer, the size of a recording material tank (e.g., an ink tank or a hopper) may be increased. In fig. 8a, a print cartridge with a standard hopper 810 is shown with a standard yield, while in fig. 8b, an extended yield print cartridge with an enlarged hopper 820 is shown.

Another way to change the print yield of a print cartridge is to change the efficiency of its components. For example, in a toner cartridge, changing the doctor blade, doctor blade gap, PCR, developer roller, OPC, supply roller, or toner may improve cartridge yield. In an inkjet printer, changing the nozzles, ejector mechanisms, ink, or ink reservoirs can change the ink cartridge throughput.

Typically, the OEM writes information into the memory that prevents the cartridge from being reused after use. Therefore, refilling a print cartridge typically requires replacement of the print chip in order to work properly. When a print cartridge has increased printing capacity, the memory must indicate this in order to ensure that the print cartridge will operate for its entire life.

FIG. 6 illustrates one method of refilling a toner cartridge. The method includes determining a storage capacity or limit of a waste bin 600. The toner coverage efficiency is determined 610. The maximum amount of toner that can be loaded into the toner hopper is determined 620 based on the waste bin capacity, hopper capacity, and efficiency of the toner. The toner hopper is loaded with an amount of toner 630 greater than the amount the cartridge was initially loaded but not greater than the determined maximum amount of toner. The memory of the cartridge chip is loaded with data relating to the amount of toner loaded in the cartridge. The method provides a toner cartridge with increased print yield that will work properly in an OEM printer.

FIG. 7 illustrates another method of refilling a toner cartridge. The method includes determining 700 a toner capacity of a waste bin. Toner 710 having a predetermined coverage efficiency is selected. The maximum amount of toner is determined based on the waste bin capacity and the coverage efficiency 720. The cartridge chip is loaded with data corresponding to the determined maximum amount of toner 730. The hopper is loaded with a maximum amount of toner 740. Alternatively, the cartridge chip may be loaded with data corresponding to an amount of toner less than the maximum amount of toner, and the hopper may be loaded with an amount of toner matching the data.

A refilled toner cartridge was obtained using one of the methods described above. The toner cartridge has a waste bin having a toner capacity and a hopper having a toner capacity. The hopper is initially loaded with toner having a coverage efficiency. The ink cartridge has a cartridge chip including a memory for storing information indicating an amount of toner loaded in the hopper. The hopper has a greater toner capacity than the waste bin and is loaded with an amount of toner based on the capacity of the waste bin and the toner coverage efficiency.

Another method for increasing the throughput of a print cartridge will now be described. Based on the amount of recording media loaded into the cartridge, there is an expected life (or print yield) of the print cartridge. However, depending on various factors, a print cartridge may run out of recording material before or after the desired throughput has been met. If the print cartridge runs out of recording material after the expected throughput, the cartridge is removed while still maintaining the recording material. It is possible that the ink cartridge will stop printing in the middle of a print job if the ink cartridge runs out of recording material after an expected throughput. Also, in an inkjet printer, when there is no ink available, the recording head is damaged to try which printing. Thus, OEMs typically set the data in memory so that the toner or ink level will last after an empty cartridge warning (outlast).

To increase the yield of the cartridge, the data in the cartridge chip memory may be set to more closely match the predicted yield of the print cartridge. Therefore, when the printer instructs the print cartridge that there is no recording material, less recording material will remain in the print cartridge.

The above described method and apparatus may also be used in managing a printing system (MPS). A management printing system is a system in which all devices of an entity are monitored and maintained by a single party. Typically, third party vendors or information technologists use software to monitor networks of devices, including printers, copiers, scanners, facsimile machines, and scanners. The MPS may route work and results across the network to ensure the most efficient use of resources. The MPS also monitors the status of the devices and maintains the devices. For example, MPS providers can monitor remaining life in print cartridges, paper usage, and other maintenance related information.

MPS uses software to manage the network of peripheral devices. The MPS can operate the printer and direct the printer to look for code stored in the memory of the cartridge chip. This allows the memory of the replacement chip to include additional information beyond the OEM chip without inhibiting the operation of the chip. When the code is detected, the MPS provider determines that the printer is loaded with high-volume cartridges. The MPS system can accurately track the amount of recording material left in the ink cartridge and command replacement of the ink cartridge at an appropriate time. The MPS may update the individual printers with accurate information or allow the individual printers to have inaccurate status information.

Fig. 9 illustrates a prior art simplified print network, such as an MPS system. The local network 900 comprises several printing devices 910a, 910b, 910c, 910d each provided with a diagnostic unit for collecting data. The local processor 920 is connected to the local network 900 via a wired or wireless connection 930 and in part via an internet connection 940 with a firewall 950.

Although it is described that each of the printing apparatuses is provided with the diagnostic unit, it is not necessary that each printer has the diagnostic unit. In this case, a computer that controls the use of the printing apparatus may be used as a diagnostic unit for some data. Also, a virtual printer or print queuing (spooling) device may be connected to the printer for use in diagnostics. The virtual printer device may be a physical device or may be software provided in a computer or via a network. The virtual printer communicates with the printer and with one or more devices connected to the printer.

The local processor may be a particular computer managed by a particular person or group of persons, or may be a central computer or server.

In this illustration, the local processor is the specific computer 970. The computer may include software containing specific instructions for at least periodically collecting data from the printing devices 910a-d and for storing the data on an external removable data storage device, such as a USB flash drive, USB key, or other storage device provided with a USB port for connecting the storage device to a USB port of the local computer 970. Alternatively, the computer may communicate the stored data to an external device or network via the internet connection 940.

The storage device 980 connected to the local computer 970 may include instructions readable by the computer 970 to enable the local processor to execute programs or software when encoding or storing data from the various printing devices, and which further serve to process the data for compiling another or revised file store, advantageously including a store of at least a portion of the history of the file, such as status monitoring reports and their history.

When the storage means is provided with the latest data from the printing means, said data may be processed by a computer, such as a computer of a local area network, a personal computer possibly adapted to be connected to a local area network, a remote computer (e.g. a computer receiving data via the internet) or the like. Alternatively, the processing occurs at an external device or network when the storage device is not used.

When the processing is performed in a computer connected to the local area network, the data of the printing device and the processed data are advantageously placed in one or more storage devices accessible to authorized persons via the local area network.

When the processing of the data is performed in a computer that is not part of the local area network, the storage 980 may be used by the provider of the material to analyze said data in his computer or in a remote network in order to analyze the steps to be performed. The data of the storage device can also be transmitted to an external computer through the internet.

An improved method for using the system of fig. 9 is described below. The authorizer or crowd of clients of the local area network or the maintenance authorizer or crowd of the printing device of the client plugs into the client processor 970 via the USB key 980. The client processor reads the contents of the USB key 980 to initiate a process of searching for data from the various printing devices of the local network. The printing devices each have a diagnostic unit that is queried or asked via the local area network to obtain at least some data therefrom. Alternatively, each printing device communicates with a single device that performs diagnostics. In addition, the program may search for some data relating to the local area network itself, for example, the location of the printing device in the local area network, and may access the computers of the local area network of the printing device.

The contents of the external storage device are accessed via the client processor to initiate a program or software contained in the external storage device or to initiate an internet communication to connect the local processor to the external processor using the collection program or software. To access the contents of the external storage device, one or more passwords are required to be introduced. The client processor now starts the information collection system.

The external storage device may contain security features to protect access to the data, such as requiring submission of a username and password. The security features may include one or more biometric security devices, such as fingerprint scanner 960, connected directly to a computer port (such as part of a USB device) or integrated into another electronic device (such as external storage device 980). Security may also be enhanced by encrypting communications between the various electronic devices, particularly communications transmitted over a network, with encryption hardware (not shown), by encryption software stored on external storage device 980 and executed on processor 970, or both.

One problem associated with the MPS system described above is that the system relies on printer firmware loaded in the printer. Typically, the printer firmware communicates with a chip located on the print cartridge. The communication may have many functions. Initially, the cartridge chip may transmit to the printer authentication information that verifies that the print cartridge is suitable for use in the printer. The cartridge chip may also include stored data. The data may include information such as cartridge production date, cartridge configuration, and printing material load.

In many printers, during normal operation, the printer initially communicates with a newly installed ink cartridge to confirm that the ink cartridge is authorized for use in the printer. After the verification is complete, the printer monitors the print job and calculates the amount of pixels printed during the print job. The pixel count is then stored in memory on the cartridge chip. When the predetermined image count is reached, the printer displays a low toner or low ink warning. The warning prompts the user to replace the ink cartridge. The user then contacts the MPS provider to provide a new print cartridge and install the new print cartridge into the printer.

FIG. 10 illustrates a system that monitors one or more printers connected to a network. The printing device is connected to one or more processors through a server. The server may be an MPS server or a virtual printer. Each of the processors has installed software that acts as client software. The client software sends all print data to the server. The server identifies the cartridge type of each printing device connected to the network. The server analyzes the print data received from the client software and converts the print data to a pixel format and calculates consumable usage based on the identification criteria and pixel count. The server is connected to an external source, such as a web page, for monitoring usage information and enabling updates to the server. The server may contain a general purpose print driver or may convert the print job into a pdf format in order to simplify operations.

Fig. 11 illustrates an example of data stored in the ink cartridge and readable by the printer. For example,the cartridge has a chip with a memory that stores data read by the printer. The following table describes some information stored for some addresses.

Address	Function(s)
		00	Device ID
01	Color ID
		02	Additional color ID
07	Ink cartridge area
		0A	Indicating tape starter or starter-free ink cartridge
03,04,0B,18,1C,22,26,2D,58,5E,66,78	Data that cannot be changed. Printer reports and errors.
		0C-12,21	May be changed, but the printer reports "non-genuine ink cartridge"
20,28,2A,2B,2E,2F,5C,79	May be changed to 00. The printer reports "certified HP".
		19 to 1B	Date of installation and production.
1D to 1F	Ink cartridge serial number.
		23,24	Initial volume of ink cartridge
25	Ink cartridge retention time.
		27	The ink cartridge color ID is appended.

The cartridge identification may be data stored in the printer. Some of the data in the memory is read by the printer and affects the performance of the printer. Other data, such as the data stored in addresses 20, 28, 2A, 2B, 2E, 2F, 5C, 79 in the printer, do not affect the performance of the printer. The cartridge identification is data that is different from the original data of the OEM cartridge. Therefore, it is preferable that the cartridge identification should be stored in an area that does not affect the performance of the printer. For example, the cartridge identification may be stored in the address ID to IF as a unique serial number (i.e., other than the OEM serial number) that is recognized by the MPS system or the virtual printer. Alternatively, another area of the memory may be loaded with data identified as cartridge identification. For example, the expiration date may be some future or past date identified as the cartridge identification, such as 3060 years 12 months 1 days. Any field read by the printer may contain data that serves as an identifying job. Alternatively, an address of 00 or FF, which is typically not read by the printer, may be used to store the cartridge identifier. The MPS or virtual printer may cause the printer to read addresses that are typically ignored.

If the printer cartridge installed in the printer is a remanufactured print cartridge, the printer may prematurely issue a low toner (or ink) warning. For example, if the print cartridge is an extended yield recycled toner cartridge, the printer may display low toner after 4000 pages are printed. However, a recycled toner cartridge may be able to print 6000 pages before running to a toner-low situation. In this example, toner is removed with 2000 pages of print life remaining. This results in more frequent cartridge replacement, cartridge refilling, and wasted toner.

Current systems enable MPS to more accurately calculate or predict the end of life of a print cartridge. As described above, the cartridge chip includes an identification code that can be read by the MPS or virtual printer. The cartridge code identifies the cartridge of the MPS system. The MPS system can then determine the ink cartridge characteristics. These characteristics may include cartridge size, toner load, ink load, manufacturer identification, production date, reproduction identification, reproduction date, toner characteristics, ink characteristics, expected cartridge yield, and other desired information.

The identification code may be data stored in memory, a bar code or other machine readable information, an RFID tag, a user input, or any other suitable means for identifying the cartridge. Also, the identification code may be associated with a print cartridge that does not include a cartridge chip or memory. The identification code may be placed on the print cartridge where it fits and wirelessly communicates with the MPS or virtual printer.

An MPS or virtual printer is used to monitor the communication between the processor and the printer or imaging device. These communications are used to determine details about the print job, such as the number of pages printed and the density of the images printed. Then, the virtual printer calculates a plurality of pixels to print based on the print job information. The virtual printer may store this information on external storage 880 or send the information to the MPS provider. Each time the printer is used for printing, the virtual printer repeats these steps and calculates the total number of pixels printed by the printer. When the printer prints a total number of print pixels that matches the threshold expected yield of the print cartridge, processor 870 sends a message to the MPS provider to provide a replacement cartridge and a message to the printing user to command the replacement cartridge.

Another advantage of this system is that any information can be associated with the cartridge identification. This enables the system to determine toner or ink usage with much greater accuracy. For example, an electrostatic printer in a climate control office will print documents with a certain milligram of toner per page. For example, a printer in an office may print a text document with an average of 9mg of toner per page. However, the same printer located in a taller and more humid warehouse or production facility will use more toner. Furthermore, if the same printer is used to print graphics, it will use one third of the amount of toner per page. The same example applies to an ink printer.

Current systems allow the use of the printer or cartridge and environmental information to be used to determine a more accurate ink or toner count. For example, if the printer is located in a warehouse in southern florida, the system adjusts the toner count to compensate for the high heat and high temperature conditions.

Another advantage of the present system is that it enables more efficient use of network resources. In many enterprise environments, there are one or more printing spaces that house a variety of printing devices. Typically, for convenience or custom, a user sends a document to the same printer. Current systems allow a virtual printer to select the best printer for a print job.

For example, user a needs to print a five hundred page text document. User a selects printing and sends a print job to the virtual network printer. The virtual network printer then monitors the printers to which user a is able to print. The virtual printer selects the printer that is most efficient for printing text documents and has sufficient ink in the cartridge to print the entire file. When the print job is completed, the virtual printer displays the print job completion together with the position of the print job on the monitor of the user a.

In another example, user A prints a large monochrome text document and a presentation (presentation) containing multi-color graphics. The virtual printer may select two different printers to print user A's documents, the most efficient printer for monochrome text and the multicolor graphics printer. Then, the virtual printer displays the position of the print job on the monitor of the user a.

Alternatively, the system may queue (spool) print jobs to the printer to optimize the performance of the printer. For example, in a laser printer, it is more efficient to print pages continuously than to wait for one page to be printed for a short period of time and then print another page. The virtual printer may monitor and send print jobs to the printer to enable the printer to continuously print pages. This prevents additional wear on the individual printers.

Another example of a system is to reduce the cost of the MPS provider. Typically, MPS providers estimate the cost of printing a page. The estimation is based on the average print job of the client. The MPS provider then charges its clients the computational cost per page plus some additional fee. The surcharge is the profit of the MPS provider. Current systems allow MPS providers to reduce the cost per page by enabling the print cartridge used to be closer to the end of actual life. In addition, the current system allows the MPS provider to better calculate the amount of toner used per page and the type of toner used per page. This allows the MPS provider to more accurately determine the cost of each page. This in turn allows the MPS provider to reduce the cost of charging the client. Furthermore, the system even allows the MPS provider to charge a fee per toner system rather than per page model.

In another embodiment, the presence of the identification allows the virtual printer or MPS system to reset the printer at some point in the life of the cartridge. In many printers, when the pixel count reaches a predetermined threshold level, the print cartridge is deemed empty and the printer will no longer allow the print cartridge to be used for printing. This type of system prevents the extended-yield remanufactured print cartridge from being used for its full print life. A method of alleviating this problem will be described below.

Extended life (or high throughput) regenerative print cartridges are loaded into a printer. The cartridge chip communicates with the printer to verify if necessary. The virtual printer reads the cartridge chip identification and determines the expected print life of the print cartridge. The virtual printer monitors communications with the printer as described above to determine the precise pixel count, the amount of toner used, or the ink used. Finally, after the printer determines that the print cartridge has printed the number of pages or pixels that the standard print cartridge should print, the printer disables printing by the print cartridge. The virtual printer receives the printer out of paper status and determines that the printer cartridge is an extended life cartridge and still has printing material therein. The virtual printer sends a signal to the cartridge chip telling the chip to reset to the chip with the printed material therein. The virtual printer then causes the printer to reset, or power off and restart, to re-read the cartridge chip. The printer reads that the cartridge chip still contains printing material, allowing printing to continue.

In the alternative, the virtual printer requests the user to power down the printer and restart or open and close the printer cover. This allows the user to prompt the printer to authenticate the chip if the virtual printer is unable to force the printer to restart. Alternatively, the virtual printer can request user intervention if the automatic restart improperly resets the printer.

Another advantage of the present system is that it allows customized messages to be provided to the user. Many conventional printers communicate the ink or toner level to the user via a message displayed on a computer monitor. The printer sends a signal to the connected processor to display information such as "toner low", "ink low", or "change cartridge". Also, a message providing ordering information such as the type of ink cartridge may be displayed or the computer may take the user to an internet website to order a new ink cartridge. Current systems enable customized information to be displayed to a user. This may include all information that a typical printer may display. The printer may also provide additional information such as total pages printed, monthly expenses, cartridge remanufacturers, or any other desired message.

One way that printers communicate information to a user is via a screen or display located on the printer. For example, many printers have a display located on the printer. The display may convey information regarding the status of the printer, the print job, an out of paper indicator, an out of ink or toner indicator, or any other desired information. A second way that printers communicate information to users is via a monitor connected to the user's computer. For example, a printer sends information to a user's computer. The computer then causes the connected monitor to display. A third way that printers communicate information to users is by printing the information onto a recording medium. For example, some printers automatically print status feed pages when a new cartridge is loaded into the printer or when the ink or toner level in the cartridge reaches a predetermined low level. The status supply page conveys information such as the cartridge model number, the number of pages that the cartridge can print.

The printer uses internal programming to control the operation of the printer, communication between the printer and connected devices, display of information on the display of the printer, and printing of the supply status page. In many conventional printers, internal programming may be written or modified using a standardized programming language such as Printer Control Language (PCL) or Printer Job Language (PJL). Some printers use PJL to enable switching of printer languages at the work level, and to enable status feedback between the printer and the computer or processor. Hewlett packardPJL was developed and incorporated by introduction "The use thereof is described in Printer Job Language Technical Reference Manual. Using PJL, the user can develop applications that can switch printer languages, monitor printer status, request information such as printer model and configuration, change control panel default settings, modify control panel messages, and other needed modifications to the printer.

Current systems may use applications written in the PJL to control the information displayed by the printer. For example, a printer has a printer cartridge loaded therein, the printer cartridge having an identification associated therewith. The cartridge identification indicates to the virtual printer or MPS system characteristics about the cartridge, such as its expected page yield, the remanufacturer of the print cartridge, and a website URL with information ordering the cartridge for replacement. The applications written into the PJL are stored on the processor, on a memory peripheral device, or on a network. The application is used to communicate with the printer to change the supply status page that the printer will print. The printer prints a supply status page indicating an expected page yield of a specific ink cartridge, a company supplying or reproducing the ink cartridge, information ordering the ink cartridge from a supplier, based on the cartridge identification.

In addition, the stored application, or an additional application, may use the PCL or PJL to control the messages communicated to the user by the printer via the connected processor and its display. For example, a printer has a printer cartridge loaded therein, the printer cartridge having an identification associated therewith. The cartridge identification indicates to the virtual printer or MPS system characteristics about the cartridge, such as its expected page yield, the remanufacturer of the print cartridge, and a website URL with information ordering the cartridge for replacement. The application written in the PJL is stored on the processor, on a peripheral device, or on a network. The application is used to communicate with the printer to change the information that the printer delivers to the connected processor. The new delivery information causes the processor to display on the user's monitor information indicating an expected production volume of a particular ink cartridge, a remaining amount of printing material, a company supplying or reproducing the ink cartridge, information ordering the ink cartridge from the supplier, and a web link ordering the new ink cartridge based on the cartridge identification.

In the above example, any desired information may be printed on the feed status page or displayed on the monitor. Additional forms of communication may be used. For example, the printer may cause the processor to send an email or play an audio signal conveying the desired information.

In other embodiments, the cartridge chip includes a communication device. The communication device may be a bluetooth device, a wireless internet card, RFID, or any other manner of communicating electronic information. In this embodiment, the wireless communication device communicates directly with the virtual printer or MPS system. Alternatively, the wireless device may communicate directly to the off-site system.

The communication means allows the virtual printer to communicate with the cartridge chip. The cartridge chip may communicate information that is typically passed only between the cartridge chip and the print driver. This allows the virtual printer to monitor the chip directly, without monitoring the communication between the processor and the printer. Using the communication means, the chip tells the virtual printer its updated status, and the exact pixel count, toner count, ink count, or page count can be calculated.

In addition, the communication device may cause the cartridge chip to reset. This will allow the cartridge chip to be reset without returning to the chip manufacturer.

Another advantage of the present system is that the system can be used to customize the operation of the printer device. In conventional printers, the printer is a closed system and internal printer firmware controls the operation of the printing device. Firmware loaded in the printer controls the operation of the printer and performs recording material usage calculation. The user's ability to control how the printer operates is limited. Generally, users are limited to controlling image quality using, for example, drafts, normal, fine, realistic (photomraphs), and the like. Also, the user may generally select a media type, such as plain paper, photo paper, special paper, and the like.

An advantage of current systems is that peripheral devices can communicate with the printer and change the way the printer operates.

For example, printer companies often update firmware used in printers to address issues that have been discovered in the operation of the printer or to address changes implemented in new cartridges. Sometimes, the updated firmware may cause other errors or cause certain ink cartridges to function improperly.

Current systems allow for correction of errors caused by firmware. In some cases, the peripheral device may access a firmware version of the printer. The peripheral device may compare the firmware version to the characteristics of the loaded cartridge in the printer. The peripheral device may perform alternative printer control functions or provide printer information based on the firmware version to optimize printing or correct errors.

For example, it may be known that a particular firmware version reports erroneous cartridge production information. The peripheral device can correct the erroneous information and provide the correct information. The peripheral device may alter operation if the identified ink cartridge characteristics require different printer operations.

In another embodiment, the system can be used to update the firmware of the printer. In many printers, the printer prompts the user through an interface that a new version of the firmware is available. If the user accepts the new firmware, the printer obtains an updated version of the firmware via an Internet connection and updates the printer with the new firmware. Current systems allow a peripheral device to indicate to a user that new firmware is available. When the user accepts the updated firmware, the peripheral device obtains the firmware from the MPS provider and updates the firmware of the printer. Alternatively, the firmware update may be performed automatically or by the MPS representative servicing the printer.

In another embodiment, the peripheral device may change the calibration of the printer to improve the performance and print quality of the printer. The printer is calibrated to work with OEM cartridges. The OEM controls the characteristics of the ink cartridge and sets up the printer to work with the ink cartridge in a typical printing environment. Changes in the print cartridge, other internal printer components, or the printer can affect printer operation.

For example, the system includes a laser printer connected to a personal computer and peripheral devices. The user installs an after-market toner cartridge with a cartridge identification. Toner cartridges have been regenerated or filled with additional toner to increase the print yield of the cartridge. Also, the toner has different characteristics from the OEM toner.

The peripheral device knows the characteristics of the ink box through the ink box mark. The peripheral device changes the algorithm used by the printer to calculate the print yield to match the increased print yield of the recycled toner cartridge. Also, the peripheral device changes the operating voltage of the printer to match the characteristics of the after-market toner. This may be an increased voltage level or a decreased voltage. These changes allow the printer to use the aftermarket toner cartridges to print high quality images.

The peripheral and cartridge identification allow for printer optimization of the internal printer portion. The identification is not limited to cartridge identification that provides information about the print cartridge. The identification may be used to determine the printer and its interior, the print cartridge and its portion, any desired characteristics of the recording medium, the environment in which the printer is located, or the user of the printer.

For example, laser printers have many parts that affect image quality and operating characteristics. These parts may include the OPC drum, PCR roller, power supply, toner, doctor blade, and recording media. The identification may be used to identify any or all of these portions. Further, the system may use multiple identities.

For example, a system may include an ink cartridge having an ink cartridge identification and a user identification. The cartridge identification is used to determine the cartridge characteristic and the user identification is used to determine the user characteristic. The user characteristics may include typical usage, documents that are typically printed, the environment in which the printer is located, scheduled maintenance that is typically used on the printer, and the type of recording material used for printing.

While the above systems and methods describe a virtual printer or MPS, the present invention is not limited to use with either. The system may be implemented using software loaded onto a network server, software loaded onto a separate processor, or a remotely located system that is remotely contacted via the internet or a communication line. Further, the system and method may be implemented on a single imaging device connected to a single processor or a single imaging device connected to a home network. Additionally, the system may be used with any type of imaging device connected to a processor. This includes ink jet printers, electrostatic printers, facsimile machines, digital copiers, printing devices that print three-dimensional models, and all-in-one machines.

The many features and advantages of the invention are apparent from the detailed specification. Accordingly, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described. Accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.

While the invention has been illustrated by reference to specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the scope of the invention. The invention is intended to be broadly protected within the spirit and scope of the appended claims.

Claims (21)

1. A system for determining an accurate amount of consumable in a print cartridge, the system comprising:

a printing device into which a print cartridge is loaded, wherein the print cartridge has a cartridge identification associated therewith, wherein the print cartridge has an expected print yield that is different from an expected print yield of a standard yield cartridge produced for use in the printing device;

a processor; and

a peripheral device external to the printing device and the processor and communicably connected between the printing device and the processor to monitor communication between the processor and the printing device, wherein the peripheral device calculates a pixel count to be printed by the printing device by monitoring communication between the processor and the printing device to determine an accurate remaining consumable amount.

2. The system of claim 1, wherein the peripheral device determines specific information about the printing device based on the cartridge identification.

3. The system of claim 1, wherein the peripheral device determines specific information about the print cartridge based on the cartridge identification.

4. The system of claim 1, wherein the processor is a computer connected to a management printing system for monitoring consumption of printing consumables.

5. The system of claim 1, wherein the print cartridge is a recycled cartridge that maintains a higher production of printing consumables than an original cartridge, and the printing device does not determine an appropriate consumable remaining level for the recycled cartridge, and wherein the peripheral device is connected to a managed printing system.

6. The system of claim 5, wherein the peripheral device causes the processor to display an appropriate remaining amount of printing consumables on a display.

7. The system of claim 1, wherein the print cartridge has a cartridge chip in communication with the printer, and the cartridge identification is stored in a memory of the print chip.

8. The system of claim 7, wherein the cartridge identification is a serial number different from an original equipment vendor serial number.

9. A method for determining an accurate consumable quantity in a print cartridge, wherein the print cartridge has a cartridge identification associated therewith and the print cartridge has an expected print yield that is different from an expected print yield of a standard yield cartridge produced for use in the printing device, the method comprising:

determining that a print cartridge installed in a printing device has a cartridge identification associated therewith;

determining one or more characteristics of the print cartridge based on the cartridge identification;

monitoring communication between a processor and the printing device to determine that the printing device has a printed image, wherein the processor is external to the printing device;

determining an amount of consumable material for printing the image by calculating a pixel count to be printed by the printing device; and

an accurate remaining consumable amount is determined based on the consumable amount used to print the image and the cartridge identification.

10. A system for determining an accurate amount of consumable in a print cartridge, the system comprising:

a printing device having a print cartridge loaded therein, wherein the print cartridge has a cartridge identification associated therewith;

a processor; and

a peripheral device external to the printing device and the processor and communicably connected between the printing device and the processor to monitor communication between the processor and the printing device, wherein the peripheral device determines an accurate amount of remaining consumable material by monitoring communication between the processor and the printing device to calculate a pixel count to be printed by the printing device regardless of the amount of remaining consumable material determined by the printer.

11. The system of claim 10, wherein the peripheral device determines specific information about the printing device based on the cartridge identification.

12. The system of claim 10, wherein the peripheral device determines specific information about the print cartridge based on the cartridge identification.

13. The system of claim 10, wherein the processor is a computer connected to a management printing system for monitoring consumption of printing consumables.

14. The system of claim 10, wherein the print cartridge is a recycled cartridge that maintains a higher production of printing consumables than an original cartridge, and the printing device does not determine an appropriate consumable remaining level for the recycled cartridge, and wherein the peripheral device is connected to a managed printing system.

15. The system of claim 14, wherein the peripheral device causes the processor to display an appropriate remaining amount of printing consumables on a display.

16. The system of claim 10, wherein the print cartridge has a cartridge chip in communication with the printer, and the cartridge identification is stored in a memory of the cartridge chip, and wherein the cartridge identification is a serial number different from an original equipment vendor serial number.

17. A system for managing printers, the system comprising:

a printing device having a print cartridge loaded therein, wherein the print cartridge has a cartridge identification associated therewith;

a processor; and

a peripheral device external to and communicably connected between the printing device and the processor, the peripheral device calculating a pixel count to be printed by the printing device by monitoring communications between the processor and the printing device, wherein the peripheral device determines characteristics of the printing device or the print cartridge based on the cartridge identification, and the peripheral device communicates information to the user that is different from information communicated to the user by the printer.

18. The system of claim 17, wherein the print cartridge is an aftermarket or remanufactured print cartridge and the information communicated to the user is a name of the cartridge provider.

19. The system of claim 17, wherein the information communicated to the user is a remaining amount of recording material in the print cartridge, and the peripheral device determines a more accurate amount than the printer.

20. The system of claim 17, wherein the information communicated to the user is information related to a print history of the printer.

21. The system of claim 17, wherein the print cartridge has a cartridge chip and the cartridge identification is stored in a memory of the cartridge chip, and wherein the cartridge identification number is a different serial number than an original equipment vendor serial number.