Contaminant removal system in a thermal processor

Information

  • Patent Grant
  • 6812947
  • Patent Number
    6,812,947
  • Date Filed
    Friday, February 28, 2003
    21 years ago
  • Date Issued
    Tuesday, November 2, 2004
    19 years ago
Abstract
A thermal processor having a contaminant removal system. The system includes a heated drum for heat developing exposed heat developable media which emit airborne contaminants during the development; a plurality of rollers located about a circumferential segment of the drum to hold an exposed media in contact with the drum; an enclosure for enclosing the heated drum and plurality of rollers, the enclosure including a first upper curved member spaced from and enclosing the rollers and the upper portion of the drum and a second lower curved member spaced from and enclosing the lower portion of the drum, the first and second curved members having first ends spaced from each other and defining a film entrance region, and further having second ends spaced from each other and defining a film exit region; wherein the first upper curved member includes a curved duct having a first opening above the rollers and a second opening configured to direct gaseous fluids away from the film exit from the drum. The system further includes a top condensation trap communicating with the second opening of the duct; a bottom condensation trap; and an air flow control system for drawing ambient air from outside the enclosure through the film entrance region, splitting the air flow into (a) a top flow stream which passes between the first member over the rollers, through the duct and through the top condensation trap where airborne contaminants are condensed and the air stream is cooled, and (b) a bottom flow stream which passes between the second member and the lower portion of the drum and through the bottom condensation trap where airborne contaminants are condensed and the bottom flow stream is cooled.
Description




FIELD OF THE INVENTION




This invention relates in general to laser imaging systems and more particularly to a contaminant removal system in a thermal processor of a photothermographic laser imaging system.




BACKGROUND OF THE INVENTION




Laser imaging systems are widely used in commercial, industrial, and medical imaging fields. In the medical imaging field, photothermographic laser imaging systems are used to reproduce digital medical images in heat processable photothermographic film. After the film is exposed to a digital medical image, the film is processed by a thermal processor to produce a visual representation of the medical image on the film. The thermal processor includes a rotatable heated drum having circumferentially arrayed pressure rollers to hold the film in contact with the heated drum during development. After development, the film is cooled and output to a user.




During the heat development process of the exposed photothermographic media, air-borne contaminants are produced that can produce image artifacts in the developed film image. Airflow in the exit region from the drum has resulted in image artifacts that have a Christmas tree type of profile or wispy appearance.




There is thus a need for improving air contaminant removal in heated drum thermal processors in order to minimize image artifacts in developed film.




SUMMARY OF THE INVENTION




According to the present invention, there is provided a solution to these problems.




According to an aspect of the present invention there is provided, a thermal processor having a contaminant removal system comprising: a heated drum for heat developing exposed heat developable media which emit air-borne contaminants during said development; a plurality of rollers located about a circumferential segment of said drum to hold an exposed media in contact with said drum; an enclosure for enclosing said heated drum and plurality of rollers, said enclosure including a first upper curved member spaced from and enclosing said rollers and the upper portion of said drum and a second lower curved member spaced from and enclosing said lower portion of said drum, said first and second curved members having first ends spaced from each other and defining a film entrance region, and further having second ends spaced from each other and defining a film exit region; wherein said first upper curved member includes a curved duct having a first opening above said rollers and a second opening configured to direct gaseous fluids away from the film exit from said drum; a top condensation trap communicating with said second opening of said duct; a bottom condensation trap; and an air flow control system for drawing ambient air from outside said enclosure through said film entrance region, splitting said air flow into (a) a top flow stream which passes between said first member over said rollers, through said duct and through said top condensation trap where air-borne contaminants are condensed and said air stream is cooled, and (b) a bottom flow stream which passes between said second member and said lower portion of said drum and through said bottom condensation trap where air-borne contaminants are condensed and said bottom flow stream is cooled.




ADVANTAGEOUS EFFECT OF THE INVENTION




The invention has the following advantages.




1. Air contaminants produced during development of heat processable exposed media in a heated drum thermal processor are removed in an efficient and cost effective manner.




2. Image artifacts are minimized in heat developed exposed media.




3. Air temperature is minimized at the filter inlet thus increasing filter life and effectiveness.











BRIEF DESCRIPTION OF THE DRAWINGS





FIG. 1

is a perspective view of a heated drum thermal processor incorporating the present invention.





FIG. 2

is a side elevational view of the heated drum assembly of the processor of FIG.


1


.





FIG. 3

is a perspective view of components of an embodiment of the present invention.





FIG. 4

is a side elevational view of components of an embodiment of the present invention.











DETAILED DESCRIPTION OF THE INVENTION




Referring now to

FIG. 1

, there is shown a thermal processor incorporating an embodiment of the present invention. As shown, thermal processor


10


generally includes a heated drum assembly


12


, a film cooling section


14


, densitometer


16


, and airborne contaminant removal system


18


. In operation, an exposed photothermographic media is heat developed by heated drum assembly


12


. The heated media is cooled while passing over cooling section


14


. Densitometer


16


reads the density control patches on developed media before the media is output to a user. System


18


removes airborne contaminants produced during the heat development process.




As shown in greater detail in

FIG. 2

, heated drum assembly


12


includes a heated drum


20


which rotates in direction


22


, a plurality of rollers


24


circumferentially arrayed about a segment of drum


20


to hold an exposed media in contact with drum


20


and enclosure


26


enclosing drum


20


and rollers


22


. Enclosure


26


includes a first upper curved cover member


28


, spaced from rollers


22


and second lower curved member


30


spaced from and enclosing the lower portion of drum


20


. Upper and lower members


28


,


30


have respective first ends


32


,


34


spaced from each other defining a media (film) entrance region


36


and respective second ends


38


,


40


spaced from each other defining a media (film) exit region


42


. Feed rollers


44


,


46


and entrance guides


48


,


50


feed an exposed film into contact with drum


20


under rollers


24


. Film diverter


52


diverts film from contact with rollers


24


to exit over perforated felt pad


54


. Top condensation trap


56


, bottom condensation trap


58


and top internal duct


60


of member


28


form part of the airborne contaminant removal system of the present invention.




According to the present invention, airflow through heated drum assembly


12


is controlled to remove airborne contaminants produced during image development. In

FIG. 2

, ambient air is drawn into enclosure


26


at film entrance region


36


. Arrows


70


,


72


,


74


denote ambient air input. The air is separated into top flow stream


76


and a bottom flow stream


78


separated by film entrance region


36


and film exit region


42


.




A negative pressure (vacuum) field is applied at the air exit regions to drive flow. At the film entrance, ambient air splits into two streams moving into the upper and lower regions. The top air stream


76


filters air from the pressure roller region and processor cover member. This stream passes above the rollers


24


and out the top internal duct


60


near the film exit region


42


. The duct plate


80


between the channel and film exit separates the top air stream


76


to maximize air flow overeat rollers


24


and minimize air pulled over the film from the processor film exit which can be a source of image artifacts (location where film loses contact from the drum


20


and starts to rapidly cool). A second air stream


78


runs below the drum


20


from the film entrance


36


. As the film exits from the drum


20


, airborne contaminants remain on the drum surface and out gas into the lower region. The lower air stream


78


sweeps out contaminants from that section where potentially high concentrations can exist. At the filtration exit region, condensation traps


56


,


58


are designed to trap air contaminants by passing cool ambient air mixed with the hot processor air which causes condensation to occur. After the air is passed through the condensation region, it is further processed by special filter(s)


90


to remove contaminants and odor. Mixing ambient air in the condensation stage cools the air which increases the effectiveness and life of filters


90


. Fan


112


established a negative air pressure to drive the air flows.




The bottom air stream


78


also aids in uniform temperature development of the film. For heat processable medical film, the metal drum


20


operates at a temperature, for example, of approximately 120+° C. and is heated by a circumambient (circumferentially uniform) resistive element heater attached to the drum


20


. The film is designed to wrap around the drum


20


a certain length depending on design constraint and 180 degrees can be used. This wrap angle in combination with the drum's rotational velocity and diameter represent the total dwell time needed to adequately develop the film. Depending on the heat transfer properties of the different materials involved such as: film material, film thickness, drum material and drum thickness; the film generally takes a few seconds to warm up to the drum's operating temperature. This warm-up time typically represents a small percent of total dwell time.




The film used can draw relatively significant amounts of heat from the drum


20


surface as it first contacts the drum


20


and warms up. Circumambient heaters can cause locations of the drum


20


to under heat and over heat when film enters the processor. In locations of early film contact, where the most significant heat load takes place, the drum temperature can-decrease while in other locations the drum temperature can increase because it is not loaded as much. The temperature controller does not correct this. In a closed loop temperature control setup, the drum temperature can be controlled to a tight temperature variation at a location on the drum, but the overall drum temperature will still vary because of the non-even heat load as the film is applied to the drum. The location where the film does not wrap the drum will have the highest temperature readings. By passing cool air through this location (bottom flow stream


78


), extra heat can be removed to help make the drum temperature more uniform.




The lower airflow stream


78


is designed to adjust flow rate depending if film is present. This is done by using the film to block some of the ambient air that mixes in the lower condensation trap. When film is present in the cooling section


14


, the vacuum pressure in the lower duct increases because the ambient air passage is partially blocked. This increases the flow rate of the air in the lower duct, extracting more heat from the lower section of the drum when film is present which balances the drum's heat load better. This also conserves energy when the film is not present since the air flow under the drum


20


is reduced which reduces the duty cycle of the heater.




Air exits the drum regions at the top internal duct


60


and bottom drum outlet


82


. As the film exits the drum, the majority of air contaminants are released from the film as it separates from the drum


20


. Strong convective forces are present which lift the gasses. In this higher concentrated region above drum


20


, airborne contaminants are removed at duct


60


. Airborne contaminants are further removed a short distance from film diverter


52


with the traps


56


and


58


.




The condensation traps


56


,


58


are shown in

FIGS. 3 and 4

. Once the airborne contaminants enter the top condensation trap they are mixed with cooler ambient air in chamber


102


to enhance condensation. The insulation


104


of the top condensation trap


56


prevents image artifacts due to temperature gradients. Once the airborne contaminants enter the bottom condensation trap


58


it is mixed with cooler ambient air


106


to enhance condensation. The cooler air


106


flows through a perforated felt pad


54


and short cooling section


108


. The top condensation trap


56


and bottom condensation trap


58


are constructed from a thermally conductive material. These traps


56


,


58


are cooled by the ambient air and are attached to the main chassis, which acts as a heat sink.




The felt perforated pad


54


performs two basic functions 1) structural support as the film is transported along film path


120


and 2) a thermally non-conductive surface. As the film is transported in this region it must be supported because to the film has low beam strength. Film that is not guided may be subjected to stresses that may cause film wrinkles and creases. Film that is cooled rapidly and/or non-uniformly may cause image artifacts. The felt pad also acts as a thermal isolator preventing rapid cooling.




The air flows from the bottom condensation trap


58


through a molded rubber hose


110


to the top condensation trap


58


and then to the filtration system


90


. The contaminant removal system requires 7.5 cfm (cubic feet per minute), for example, airflow measured at the fan


112


exhaust. The airflow is divided in half through pressure orifices located in the member


114


and the member of respective


116


condensation traps


56


,


58


. The airflow is further divided in the condensation traps 50% from the drum outlets and 50% from ambient air. Uniform airflow over the top and under the bottom of the processor drum


20


reduces any temperature gradients.




The airflow with respect to the perforated felt pad


54


is shown in FIG.


4


. As the film travels over the perforated felt pad


54


it blocks the perforated holes and diverts the airflow to the bottom of the drum


20


. This balances the thermal loading of the top and bottom of the drum surface, which decreases drum


20


temperature variations. During idle conditions the air flows through the perforated felt pad


54


mixing cooler air into the condensation traps


56


,


58


.




The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the spirit and scope of the invention.




Parts List






10


thermal processor






12


heated drum assembly






14


film cooling section






16


densitometer






18


airborne contaminant removal system






20


heated drum






22


direction






24


rollers






26


enclosure






28


,


30


curved cover member






32


,


34


first ends






36


film entrance region






38


,


40


second ends






42


region






44


,


46


rollers






48


,


50


entrance guides






52


film diverters






54


perforated felt pad






56


top condensation trap






58


bottom condensation trap






60


top internal duct






70


,


72


,


74


arrows






76


top air stream






78


bottom air stream






80


duct plate






82


bottom drum outlet






90


special filters






102


chamber






104


insulation






106


cooler ambient air






108


short cooling section






110


molded rubber hose






112


fan






114


top orifice






116


bottom orifice



Claims
  • 1. A thermal processor having a contaminant removal system comprising:a heated drum for heat developing exposed heat developable media which emit air-borne contaminants during said development; a plurality of rollers located about a circumferential segment of said drum to hold an exposed media in contact with said drum; an enclosure for enclosing said heated drum and plurality of rollers, said enclosure including a first upper curved member spaced from and enclosing said rollers and the upper portion of said drum and a second lower curved member spaced from and enclosing said lower portion of said drum, said first and second curved members having first ends spaced from each other and defining a film entrance region, and further having second ends spaced from each other and defining a film exit region; wherein said first upper curved member includes a curved duct having a first opening above said rollers and a second opening configured to direct gaseous fluids away from the film exit from said drum; a top condensation trap communicating with said second opening of said duct; a bottom condensation trap; and an air flow control system for drawing ambient air from outside said enclosure through said film entrance region, splitting said air flow into (a) a top flow stream which passes between said first member over said rollers, through said duct and through said top condensation trap where airborne contaminants are condensed and said air stream is cooled, and (b) a bottom flow stream which passes between said second member and said lower portion of said drum and through said bottom condensation trap where airborne contaminants are condensed and said bottom flow stream is cooled.
  • 2. The thermal processor of claim 1 wherein top condensation trap and said bottom condensation trap are connected together to form a continuous path for said top and bottom and air flow streams.
  • 3. The thermal processor of claim 1 including a filtration system connected to said traps for filtering said air flow passing through said traps.
  • 4. The thermal processor of claim 1 wherein said air flow control system includes an air mover system for creating a negative air pressure to draw air through said air flow system.
  • 5. The thermal processor of claim 1 wherein said airflow control system draws ambient air from outside said traps into said traps to cool the air passing through said traps.
  • 6. The thermal processor of claim 5 including a film diverter located at said film exit for removing developed film from contact with said heated drum, a perforated felt pad for supporting film after removal from said drum, said pad being in air communication with said bottom condensation trap, wherein when film travels over said felt pad, said perforations are blocked and said airflow is diverted to the bottom of the drum to decrease drum temperature variations.
US Referenced Citations (3)
Number Name Date Kind
3757662 Ingels Sep 1973 A
5790069 McDaniel et al. Aug 1998 A
5946025 Allen Aug 1999 A
Foreign Referenced Citations (2)
Number Date Country
06332142 Feb 1994 JP
WO 9721150 Jun 1997 WO