Patent Grant
7840170
This application is related to the application entitled “Apparatus and Method for Metering Fluid Film in an Ink Jet Printing System,” and the application entitled “Liquid Supply Systems, Fusers and Methods of Supplying Liquids in Printing Apparatuses,” each of which is filed on the same date as the present application, each of which is commonly assigned to the assignee of the present application, and each of which is incorporated herein by reference in its entirety.
Disclosed herein is an apparatus and method that meters fluid film in an image fusing system that fuses or fixes marking material images onto print media substrates, such as fusing toner onto paper in xerography, or a system that levels or fixes liquid-ink images in ink-jet or offset printing.
Presently, in electrophotographic and other printing processes, an image is typically recorded in the form of a latent electrostatic image upon a photosensitive member. The latent image is subsequently developed on the photosensitive member by applying electroscopic marking particles, commonly referred to as toner. The toner image is then transferred from the photosensitive member to media, such as a sheet of paper. The transferred image is then affixed or fused to the media, for example, by using heat and pressure applied using a fuser assembly, such as a fuser roll or belt.
Polydimethylsiloxane (PDMS) or other release fluid or agent can be used to promote release of the toner and media from the fuser assembly surface, which can extend the usable life of the fuser assembly. Unfortunately, excessive amounts of release fluid on the fuser assembly surface can transfer to the media and contaminate it. Applying a correct amount of release fluid to the fuser assembly using a release agent management system can mitigate transfer to the media, optimize post processing performance, and lower run costs for a user.
For example, fuser assemblies using release fluid can produce 2 to 100 ml of the release fluid on media. High levels of release fluid application on the media is deleterious to achieving good performance for numerous post printing operations, such as hot melt adhesive application for book binding, hot and cold laminating film application, mailing tab and label application, pressure seal application, and other printing operations. Lower release fluid levels broaden the scope of the applications that can be used on prints. On the other end of the spectrum some media demand the higher levels of release fluid on media in order to deliver acceptable fuser assembly life and performance. Unfortunately, release fluid application rates are not adjustable in the machine either automatically or manually.
A release agent management system that controls the amount of release fluid consists of a hard roller and a rubber roller for applying release fluid to the fuser assembly surface. The amount of release fluid is controlled by a metering blade riding the hard roll. This blade is critical for controlling the quality and uniformity of the release fluid. However, blades that produce acceptable films are typically difficult to manufacture, due to the edge quality requirements. Insufficient blade edge quality causes a printing system to become susceptible to producing streaks from high levels or low levels of release fluid. Dry streaks and dirt problems are exacerbated by trying to run the system at low levels of release fluid application.
For example, attempts to reduce the fluid application rate in a conventional release agent management system usually entail making the metering blade edge sharper, reducing the fluid viscosity, increasing the metering blade tip loading, and/or making a metering roller smoother. All of these management attempts can lead to increased frequency of streaks and dirt problems. To elaborate, as the ratio between blade defect size and the nominal fluid film thickness approaches 1:1 and greater, any manufacturing defect in the blade edge produces a wet streak from a hole or depression in the blade, and a dry streak from a protrusion or dirt on the edge of the blade. In addition, sensitivity to dirt and other debris increases as the fluid film thickness is decreased and increased streaking occurs when the debris lodges under a blade contact point at a roller. The streaks can impact image quality and precipitate a service call for release agent management system servicing.
While a fuser fluid reducing roller could be added to a fuser assembly system, problems with such an addition can include spatial constraint problems. A release fluid donor roller in such a system is only so large, which limits the placement position and the number of reducing rollers that can be accommodated within a specific geometry. Furthermore, while additional rollers could be placed around the release fluid donor roller, the additional rollers can hinder the ability to use gravity to return the release fluid to a release agent management pan.
Thus, there is a need for a method and apparatus that meters fluid film in an image fusing system.
A method and apparatus that meters fluid film in an image fusing system is disclosed. The apparatus can include a source of fluid film and a source metering roll rotatably supported in the apparatus. The source metering roll can have a source metering roll surface coupled to the source of fluid film, where the source metering roll surface can be configured to transport fluid film from the source of fluid film. The apparatus can include a donor belt having a donor belt surface coupled to the source metering roll surface. The donor belt surface can be configured to transport fluid film from the source metering roll surface. The apparatus can include a second metering roll rotatably supported in the apparatus. The second metering roll can have a second metering roll surface coupled to the donor belt surface, where the second metering roll surface can be configured to transport fluid film from the donor belt surface. The apparatus can include a fuser assembly having a fuser assembly surface coupled to the donor belt surface. The fuser assembly surface can be configured to transport fluid film from the donor belt surface and the fuser assembly can be configured to fuse an image on media.
In order to describe the manner in which advantages and features of the disclosure can be obtained, a more particular description of the disclosure briefly described above will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. Understanding that these drawings depict only typical embodiments of the disclosure and are not therefore to be considered to be limiting of its scope, the disclosure will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The embodiments include an apparatus for metering fluid film in an image fusing system useful in printing. The apparatus can include a source of fluid film and a source metering roll rotatably supported in the apparatus. As the terms are used herein, belts may be rolls and vice-versa for rotating members. The source metering roll can have a source metering roll surface coupled to the source of fluid film, where the source metering roll surface can be configured to transport fluid film from the source of fluid film. The apparatus can include a donor belt having a donor belt surface coupled to the source metering roll surface. The donor belt surface can be configured to transport fluid film from the source metering roll surface. The apparatus can include a second metering roll rotatably supported in the apparatus. The second metering roll can have a second metering roll surface coupled to the donor belt surface, where the second metering roll surface can be configured to transport fluid film from the donor belt surface. The apparatus can include a fuser assembly having a fuser assembly surface coupled to the donor belt surface. The fuser assembly surface can be configured to transport fluid film from the donor belt surface and the fuser assembly can be configured to fuse an image on media.
The embodiments further include an apparatus for metering fluid film in an image fusing system. The apparatus can include a media transport configured to transport media and a marking module configured to mark an image on the media to produce marked media. The apparatus can include a source of release agent and a source metering roll rotatably supported in the apparatus. The source metering roll can have a source metering roll surface coupled to the source of release agent and the source metering roll surface can be configured to transport release agent. The apparatus can include a donor belt having a donor belt surface coupled to the source metering roll surface at a source nip. The donor belt surface can be configured to transport release agent from the source metering roll. The apparatus can include a second metering roll rotatably supported in the apparatus, where the second metering roll can have a second metering roll surface coupled to the donor belt surface at a second metering roll nip. The second metering roll surface can be configured to reduce release agent transported from the source metering roll on the donor belt. The apparatus can include a fuser assembly having a fuser assembly surface coupled to the donor belt surface at a fuser nip. The fuser assembly surface can be configured to transport reduced release agent transported from the donor belt and the fuser assembly can be configured to fuse the image on the marked media.
The embodiments further include a method of metering fluid film in an apparatus having a source of release agent, a source metering roll rotatably supported in the apparatus where the source metering roll can have a source metering roll surface coupled to the source of release agent. The apparatus can include a donor belt having a donor belt surface coupled to the source metering roll surface and can include a second metering roll rotatably supported in the apparatus. The second metering roll can have a second metering roll surface coupled to the donor belt surface. The apparatus can include a fuser assembly having a fuser assembly surface coupled to the donor belt surface. The method can include transporting source release agent from the source of release agent on the source metering roll surface and transporting donor belt release agent on the donor belt surface from the source release agent on the source metering roll surface. The method can include reducing release agent on the donor belt surface by transporting second metering roll release agent on the second metering roll surface from the donor belt release agent on the donor belt surface to obtain reduced release agent on the donor belt surface. The method can include transporting fuser assembly release agent on the fuser assembly surface from the reduced donor belt release agent on the donor belt surface and fusing an image on media using the fuser assembly.
The apparatus 100 can include a donor belt 140 having a donor belt surface 142 coupled to the source metering roll surface 122. The donor belt surface 142 can be configured to transport fluid film from the source metering roll surface 122. The apparatus 100 can include at least one second metering roll 150 rotatably supported in the apparatus 100. The second metering roll 150 can have a second metering roll surface 152 coupled to the donor belt surface 142. The second metering roll surface 152 can be configured to transport fluid film from the donor belt surface 142. A second metering roll blade 154 can be coupled to the second metering roll surface 152. The second metering roll blade 154 can be configured to remove an amount of fluid film from the second metering roll surface 152. The second metering roll blade 154 can be variably coupled to the second metering roll surface 152 to vary the removal of fluid film from the second metering roll surface 152 by the second metering roll blade 154. The second metering roll blade 154 can also be decoupled from the second metering roll surface 152.
The second metering roll surface 152 can be detachably coupled to the donor belt surface 142. Thus, a number of metering rolls engaged with the donor belt surface 142 can be varied to provide for variable fluid film delivery rates. For example, the apparatus 100 can include a third metering roll 160 rotatably supported in the apparatus 100. The third metering roll 160 can have a third metering roll surface 162 coupled to the donor belt surface 142. The third metering roll surface 162 may be detachably coupled to the donor belt surface 142. The third metering roll surface 162 can be configured to transport fluid film from the donor belt surface 142. A third metering roll blade 164 can also be coupled to the third metering roll surface 162. Additional metering rolls may also be coupled to the donor belt surface 142.
The second metering roll 150 can be configured to return fluid film to the source of fluid film 110. For example, the second metering roll 150 can use gravity, a belt, a pump, or other methods to return the fluid film to a release agent management pan (not shown) of the source of fluid film 110. The second metering roll blade 154 can also be used return the fluid film to the source of fluid film 110. Additionally, multiple metering rolls coupled to the donor belt surface 142 can return the fluid film to the source of fluid film 110.
The apparatus 100 can include a fuser assembly 170 having a fuser assembly surface 172 coupled to the donor belt surface 142. As used herein, a “fuser assembly” shall be defined as any assembly that can transport fluid film and generate an image on media. For example, a fuser assembly can be a rotatable print assembly, such as a fusing member like a fuser roll or a fuser belt, a print drum, or any other assembly that can transport fluid film and generate an image on media. The fuser assembly surface 172 can be configured to transport fluid film from the donor belt surface 142. Thus, the source metering roll 120 can transport fluid film from the source of fluid film 110 to the donor belt 140, which can transport fluid film from the source metering roll 120 to the fuser assembly 170. The second metering roll surface 152 can be configured to reduce fluid film on the donor belt surface 142 by transporting fluid film away from the donor belt surface 142. The second metering roll surface 152 can reduce the fluid film on the donor belt surface 142 transported from the source metering roll surface 122. The fuser assembly surface 172 can then transport the reduced fluid film from the donor belt surface 142.
The fuser assembly 170 can be configured to fuse an image on media 190. The fuser assembly 170 can include a pressure roll 174 coupled to the fuser assembly 170 at a fusing nip 178. The fuser assembly 170 can be heated and the pressure roll 174 can exert pressure against the fuser assembly 170 to fuse an image on the media 190.
According to a related embodiment, the apparatus 100 can include a media transport 180 configured to transport media 190 and a marking module 185 configured to mark an image on the media 190 to produce marked media. The marking module 185 can be a photoreceptor, an ink-jet print head, an intermediate transfer member, or any other marking module. The apparatus 100 can include a source of release agent 110 and a source metering roll 120 rotatably supported in the apparatus 100. The source metering roll 120 can have a source metering roll surface 122 coupled to the source of release agent 110 where the source metering roll surface 122 can be configured to transport release agent. The apparatus 100 can include a donor belt 140 having a donor belt surface 142 coupled to the source metering roll surface 122 at a source nip 126 where the donor belt surface 142 can be configured to transport release agent from the source metering roll surface 122.
The apparatus 100 can include a second metering roll 150 rotatably supported in the apparatus 100. The second metering roll 150 can have a second metering roll surface 152 coupled to the donor belt surface 142 at a second metering roll nip 156. The second metering roll surface 152 can be detachably coupled to the donor belt surface 142. The second metering roll surface 152 can be configured to reduce release agent transported from the source metering roll surface 122 on the donor belt surface 142. The apparatus 100 can include a second metering roll blade 154 coupled to the second metering roll surface 152 where the second metering roll blade 154 can be configured to remove release agent from the second metering roll surface 152. The second metering roll blade 154 can be variably coupled to the second metering roll surface 152 to vary the removal of release agent from the second metering roll surface 152 by the second metering roll blade 154. The apparatus 100 can include a third metering roll 160 rotatably supported in the apparatus 100. The third metering roll 160 can have a third metering roll surface 162 coupled to the donor belt surface 142 at a third metering roll nip 166. The third metering roll surface 162 can be configured to reduce release agent transported from the source metering roll surface 122 on the donor belt surface 142.
The apparatus 100 can include a fuser assembly 170 having a fuser assembly surface 172 coupled to the donor belt surface 142 at a fuser nip 176. The fuser assembly 170 can be a fuser roll, a fuser belt, or any other fuser assembly. The fuser assembly surface 172 can be configured to transport reduced release agent transported from the donor belt surface 142. The fuser assembly 170 can be configured to fuse the image on the marked media 190.
For example, the apparatus 200 can include a donor roll 130 rotatably supported in the apparatus 200. The donor roll 130 can have a donor roll surface 132 coupled between the source metering roll surface 122 and the donor belt surface 142 where the donor roll surface 132 can be coupled to the source metering roll surface 122 at the source nip 126 and coupled to the donor belt surface 142 at a donor belt nip 146. The donor roll surface 132 can be coupled between the donor belt surface 142 and the fuser assembly surface 172 and the donor roll surface 132 can be coupled to the fuser assembly surface 172 at a fuser nip 176. The donor roll surface 132 can be configured to transport release agent from the source metering roll surface 122 to the fuser assembly surface 172. The donor belt surface 142 can then be configured to transport release agent from the source metering roll surface 122 by transporting release agent from the donor roll surface 132 received from the source metering roll surface 122.
Embodiments can provide for reducing the amount of release fluid film applied by a donor roller release agent management system. This can be accomplished by placing several fuser fluid reducing rollers, such as the second metering roll 152, in contact with a belt system that is in contact with a donor roller. The fluid film application rate on media can then be reduced without impacting a source metering roll blade. Further fluid film reductions can also be possible using multiple fuser fluid reducing rollers than fluid film reductions that can be obtained with a single reducing roller. The use of a belt riding on a donor roll can also solve spatial problems and can allow for additional reducing rolls to be added to the system. Additional rolls can provide for more choices of fluid delivery rates by varying the number of rolls engaged at any one time.
A belt architecture can ride in contact with a donor roll, and allow the placement of multiple fluid reducing rollers. The efficiency of the system in reducing fuser fluid application rate can increase with each roller added. This concept can provide for the efficient use of space and the efficient placement of additional fluid reducing rollers.
Other related embodiments can provide for replacing a donor roll with a donor belt. The use of a donor belt can provide additional space for devices to reduce the amount of release fluid applied by a release agent management system. This can be accomplished by placing several fuser fluid reducing rollers in contact with a donor belt. The donor belt can transport fluid from a source metering roller to a fuser roller. The fluid reducing rollers can reduce the fluid application rate without impacting a source roll metering blade. Further fluid film reductions can also be possible using a donor belt with multiple fuser fluid reducing rollers than fluid film reductions that can be obtained with a single reducing roller with a donor roller. A separate belt riding in contact with the donor roll can further be eliminated and even further reductions are possible. Replacing a donor roller with a donor belt can eliminate some of the cost associated with the additional roller.
Assuming 50/50 fluid film splitting between surfaces at nips between the surfaces, a mass flow analysis of a combination of a donor belt with a donor roll indicates that the release agent amounts on the media 190 can be reduced to as low as 40% of an amount achieved without using a donor belt with a donor roll. The mass flow analysis of just the donor belt indicates that the release agent amounts on the media can be reduced up to 90% of an amount achieved without using a donor belt. The reduction in both cases can be dependent upon metering roll blade efficiency.
If blade efficiency is not 100%, lower application rates can be achieved using more rollers. Additional rollers can also make the fluid film application rate tunable in several ways, depending on the desired application rate desired. For example, the fluid film application rate can be tunable within a print job, between print jobs, or at other useful times. To further tune the fluid film application rate, fluid reducing rollers can be made addressable, which can be done by moving the rollers in and out of contact with the donor belt 140 to produce multiple variable fluid rates. Also, blade critical parameters, such as metering blade loading, can be addressable and can be adjusted to deliver the desired amount of fluid removal from a fluid reducing roll, and consequently can control the amount of fluid making it onto the media 190.
The method starts at 310. At 320, source release agent from the source of release agent is transported on the source metering roll surface. At 330, donor belt release agent is transported on the donor belt surface from the source release agent on the source metering roll surface. At 340, release agent on the donor belt surface is reduced by transporting second metering roll release agent on the second metering roll surface from the donor belt release agent on the donor belt surface to obtain reduced release agent on the donor belt surface. At 350, fuser assembly release agent is transported on the fuser assembly surface from the reduced donor belt release agent on the donor belt surface. At 360, an image is fused on media using the fuser assembly. Fusing an image on media using the fuser assembly can include transferring fuser assembly release agent to the media to assist in releasing the media from the fuser assembly. At 370, the method ends.
For example, the resulting fluid film x5 inside the paper path 720 on the fuser surface 172 in the apparatus 100 can be determined as a function of the fluid film x0 on the source metering roll surface 122 according to:
and the resulting fluid film x5 outside the paper path 730 on the fuser surface 172 in the apparatus 100 can be determined as a function of the fluid film x0 on the source metering roll surface 122 according to:
where x0 can represent the fluid film on the source metering roll surface 122 after the source metering blade 124, b can represent a blade efficiency from 0-1 where 1=100% removal of fluid film from a surface, n can represent the number of second metering rolls in contact with the donor belt 140, and xm=0. Assumptions can include a 50/50 split of fluid film on corresponding surfaces at each nip exit, no fluid film lost to external heat rolls, pressure rolls, or webs at steady state, and blade efficiency equal for all blades. The ratio for OPP/IPP fluid film on the fuser surface 172 after the fuser nip 178 when using two second metering rolls 150 and 160 and blades 154 and 164, so n=2, can then be determined according to:
where the result is 4 for a blade efficiency of 0 and the result is 22/7 for a blade efficiency of 1.
According to algebraic determinations based on the above assumptions, the fluid film x5 on the media 190 after the nip 178 is:
x5=x0/4 for n=0 and all values of b;
x5=x0/4 for b=0 and all values of n;
x5=x0/10 for n=1 and b=1;
x5=x0/22 for n=2 and b=1; and
x5=x0/46 for n=3 and b=1.
As a further example, the resulting fluid film x4 inside the paper path 720 on the fuser surface 172 in the apparatus 200 can be determined as a function of the fluid film x0 on the source metering roll surface 122 according to:
and the resulting fluid film x4 outside the paper path 730 on the fuser surface 172 in the apparatus 200 can be determined as a function of the fluid film x0 on the source metering roll surface 122 according to:
where x0 can represent the fluid film on the source metering roll surface 122 after the source metering blade 124, b can represent a blade efficiency from 0-1 where 1=100% removal of fluid film from a surface, n can represent the number of second metering rolls in contact with the donor belt 140, and xm=0. Assumptions can include a 50/50 split of fluid film on corresponding surfaces at each nip exit, no fluid film lost to external heat rolls, pressure rolls, or webs at steady state, and blade efficiency equal for all blades. The ratio for OPP/IPP fluid film on the fuser surface 172 after the fuser nip 178 when using two second metering rolls 150 and 160 and blades 154 and 164, so n=2, can then be determined according to:
where the result is 4 for a blade efficiency of 0 and the result is 17/5 for a blade efficiency of 1.
According to algebraic determinations based on the above assumptions, the fluid film x4 on the media 190 after the nip 178 is:
x4=x0/4 for n=0 and all values of b;
x4=x0/4 for b=0 and all values of n;
x4=x0/7 for n=1 and b=1;
x4=x0/17 for n=2 and b=1; and
x4=x0/37 for n=3 and b=1.
In the printing apparatus 800, the media feeder module 802 can be adapted to feed media 804 having various sizes, widths, lengths, and weights to the printer module 806. In the printer module 806, toner is transferred from an arrangement of developer stations 810 to a charged photoreceptor belt 808 to form toner images on the photoreceptor belt 808. The toner images are transferred to the media 804 fed through a paper path. The media 804 are advanced through a fuser 812 adapted to fuse the toner images on the media 804. The inverter module 814 manipulates the media 804 exiting the printer module 806 by either passing the media 804 through to the stacker module 816, or by inverting and returning the media 804 to the printer module 806. In the stacker module 816, the printed media 804 are loaded onto stacker carts 818 to form stacks 820.
The printing mechanism 911 can further include a substrate guide 961 and a media preheater 962 that guides a print media substrate 964, such as paper, through a nip 965, such as the nip 178, formed between opposing actuated surfaces of a roller 968, such as the pressure roll 174, and the intermediate transfer surface 946 supported by the print drum 948. Stripper fingers or a stripper edge 969 can be movably mounted to assist in removing the print medium substrate 964 from the intermediate transfer surface 946 after an image 960 comprising deposited ink drops is transferred to the print medium substrate 964.
A print controller 970 can be operatively connected to the printhead 942. The print controller 970 can transmit activation signals to the printhead 942 to cause selected individual drop generators of the printhead 942 to eject drops of ink 944. The activation signals can energize individual drop generators of the printhead 942.
Embodiments can provide for an efficient and cost effective way to reduce fuser fluid film rate on media while maintaining a good release surface for media on a fuser roll and alleviating dependency on metering blade edge quality. In addition, embodiments can provide a robust solution to space constraints in fuser subsystems and can provide improved method of controlling and maintaining a uniform fluid film layer on fuser inside and outside paper path areas to minimize image quality artifacts associated with switching media size.
Embodiments can incorporate a fluid reducing belt in contact with donor roll in a release agent management system. In order to provide more effective oil reduction on the fuser roll and printed media, a belt can variably be in contact with multiple reduction rollers and blades as compared to a single roll. A donor belt can also be used instead of a donor roll in a release agent management system. In order to provide more effective oil reduction on the fuser roll and printed media, the belt can be in contact with multiple oil reduction rollers and blades as contrasted with single roll. Embodiments can be used in other applications where uniform thin film of lubricant or ink is required, especially if the system is bound by special constraints. Embodiments can also be applied to other xerographic products that utilize a fluid film media release system. In addition, embodiments can be applied to other industries that rely on metering out thin film or ink that have special constraints, such as applied to other industries for metering out select amounts of lubrication.
While this disclosure has been described with specific embodiments thereof, it is evident that many alternatives, modifications, and variations will be apparent to those skilled in the art. For example, various components of the embodiments may be interchanged, added, or substituted in the other embodiments. Also, all of the elements of each figure are not necessary for operation of the embodiments. For example, one of ordinary skill in the art of the embodiments would be enabled to make and use the teachings of the disclosure by simply employing the elements of the independent claims. Accordingly, the preferred embodiments of the disclosure as set forth herein are intended to be illustrative, not limiting. Various changes may be made without departing from the spirit and scope of the disclosure.
In this document, relational terms such as “first,” “second,” and the like may be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. The terms “comprises,” “comprising,” or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus. An element proceeded by “a,” “an,” or the like does not, without more constraints, preclude the existence of additional identical elements in the process, method, article, or apparatus that comprises the element. Also, the term “another” is defined as at least a second or more. The terms “including,” “having,” and the like, as used herein, are defined as “comprising.”
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