1. Field of the Invention
The present invention relates to a drying apparatus which dries sheets with high moisture content after printing, and a printing apparatus.
2. Description of the Related Art
In a printing apparatus, a sheet should be dried after becoming wet in an image formation process. The sheet may be dried naturally or in a forced manner for short time drying. Japanese Patent No. 2657571 discloses an apparatus in which a photosensitive sheet of a silver halide photosensitive material is subject to forced drying after becoming wet in a developing process. The disclosed apparatus includes an endless belt provided along a sheet travelling direction. The endless belt rotates in contact with a back surface of the sheet. Hot air is blown on the endless belt through an ejection port to increase a temperature of the belt. This means that the endless belt is heated by the hot air. The heated belt contacts the sheet which is being conveyed and accelerates drying.
A high-speed printing apparatus prints on several tens or hundreds of sheets per minute on a DIN A4-sized sheet basis. The sheets are conveyed at average speed of several millimeters to several centimeters per second. A drying apparatus should be capable of drying each sheet in several seconds and continuing the drying operation for a long time. However, it is difficult to use the apparatus disclosed in Japanese Patent No. 2657571 for high speed continuous printing for the following reasons.
In high-speed continuous printing, the temperature of the endless belt decreases gradually as drying time elapses as illustrated in a curve B of a temperature transition graph of
If the temperature of the hot air which is blown on the endless belt is increased to achieve an increased initial temperature of the endless belt, the time until the curve B reaches the T-min may be prolonged. However, due to the upper limit permissive temperature of resistance to heat of the sheet (T-max), the temperature of the hot air cannot be increased excessively. The sheet used for printing is constituted by, for example, a receptive layer and a base film. The T-max of the sheet is, for example, 90 degrees C. and it is undesirable to heat the sheet to a temperature above the T-max.
The present invention has been made in view of the aforementioned circumstances. The present invention provides a drying apparatus which dries sheets in high-speed continuous printing.
An apparatus for drying a sheet according to the present invention includes: a rotatable belt which has an outer surface and an inner surface, a part of the outer surface being in contact with the sheet; a plurality of rollers arranged in a direction in which the sheet travels, the rollers including a first roller and a second roller which are adjacent to each other, the rollers being pressed against the outer surface with the travelling sheet being held between the rollers and the outer surface; a blowing mechanism which blows hot air on the sheet from between the first roller and the second roller; and a heating unit which includes a heating element and a contact surface which is disposed in contact with the inner surface.
According to the present invention, a drying apparatus suitable for a printing apparatus that is capable of high-speed continuous printing is provided. Since sheets can be dried reliably in high speed continuous printing, insufficient or uneven drying can be avoided.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
Hereinafter, an embodiment of an inkjet printing apparatus will be described. A printing apparatus according to the present embodiment is a high speed line printer capable of high speed continuous printing using a rolled-up continuous sheet. For example, the printing apparatus is suitable for printing a large number of sheets in a printing laboratory. The printing apparatus according to the present invention can be applied to an apparatus for silver halide photographic printing in which images are developed with liquids as well as the inkjet printing apparatus. The printing apparatus according to the present invention can also be applied to apparatuses with a printing function, such as apparatuses for manufacturing various devices.
The sheet feeding unit 53 accommodates a rolled-up continuous sheet and supplies the same. The sheet feeding unit 53 can accommodate one or more rolls, and the sheet S is drawn and supplied from any desired one of the rolls.
The printing unit 52 forms an image on the sheet by applying ink from print heads 60 on the sheet which is being conveyed. The printing unit 52 also includes a plurality of conveying rollers which convey the sheet. Each of the print heads 60 is a linear printing head constituted by an array of inkjet nozzles disposed over the maximum width of a sheet expected to be used. The print heads 60 are arranged in parallel along the sheet travelling (i.e., conveyance) direction. In the present embodiment, four print heads corresponding to cyan (C), magenta (M), yellow (Y) and black (K) are provided. The numbers of the colors and the print heads are not limited to four. The inkjet printing system may be, for example, a thermal inkjet printing system, a piezoelectric inkjet printing system, an electrostatic inkjet printing system and a MEMS inkjet printing system. The colored ink is separately supplied to each print head 60 via an ink tube from the ink tank unit 57. The cutting unit 55 is provided with a cutter for cutting the continuous sheet into predetermined unit lengths after the sheet is subject to the printing process.
The drying unit 51 heats the sheet after the sheet is subject to the printing process in the printing unit 52 and dries the applied ink in a short time. The drying unit 51 includes a belt and rollers for conveying and sending the sheet. The drying unit 51 will be described in mover detail later.
The control unit 58 includes a controller provided with a CPU, memory and various I/O interfaces. The control unit 58 further includes a user interface which is constituted by an input section and a display device. A user can input and output various types of information through the user interface. The operation of the printing apparatus is controlled in accordance with instructions from the controller of the control unit 58 or external devices, such as a host computer, which is connected to the controller via the I/O interface.
The belt 1 has an outer surface 1a and an inner surface 1b on opposite sides thereof. A part of the outer surface 1a of the belt 1 contacts the sheet S or the rollers 3. Four rollers 2 are provided in a space surrounded by the inner surface 1b of the belt 1 to support and rotate the belt 1 in an extended state. At least one of the rollers 2 is provided with driving force to rotate the belt 1. The heating unit 7 is disposed in the space surrounded by the inner surface 1b of the belt 1. The heating unit 7 includes a contact portion 5 and a heating element 6. The contact portion 5 has a contact surface 5a which is in contact with the inner surface 1b. The contact portion 5 and the heating element 6 may be provided integrally or may be provided separately. The heating element 6 may be a heater, such as a panel heater, a ceramic heater and an infrared lamp. A surface temperature of the contact surface 5a is increased to a predetermined temperature (e.g., 75 degrees C.) by the heating element 6. Since the belt 1 is in contact with and is heated by the contact surface 5a while being rotated, the temperature of the entire belt 1 can be increased. Preferably, both the belt 1 and the contact portion 5 are highly thermally conductive. Also preferably, heat is transferred from the contact portion 5 to the belt 1 with little heat loss. Thus, the belt 1 is preferably formed of, for example, heat stable fiber, such as Kevlar fiber and aramid fiber, and is coated with rubber, such as highly thermally conductive carbon-containing silicon. The contact surface 5a (i.e., the contact portion 5) is preferably formed of a metallic material, such as highly thermally conductive aluminum, copper and stainless steel, and a carbon graphite resin material.
The rollers (i.e., pinch rollers) 3 are disposed above the belt 1 in parallel along the sheet travelling direction. The rollers 3 have no driving force and follow the rotation of the belt 1. Each of the rollers 3 receives predetermined urging force and is pressed against the outer surface 1a of the belt 1. The rollers 3 are provided for the following two reasons. First, the sheet S is held firmly between the rollers 3 and the belt 1 so that the sheet is reliably conveyed in the drying unit 51. Second, since the rollers 3 press the outer surface 1a of the belt 1, the sheet S which is being conveyed is brought into close contact with the outer surface 1a of the belt 1. Further, the inner surface 1b of the belt 1 and the contact surface 5a of the heating unit 7 are brought into close contact with each other. With the close contact, the heat of the heating unit 7 will be transferred to the belt 1 with high efficiency and the heat of the belt 1 is transferred to the sheet S with high efficiency. In order to enhance these effects, three or more rollers 3 are preferably provided. Twelve rollers are provided in the present embodiment.
As illustrated in
Ejection ports 4 are provided at positions corresponding to spaces between arbitrary two adjacent rollers 3 (i.e., a first roller and a second roller). High temperature air flows (i.e., hot air) are blown on the sheet S from between the adjacent rollers 3 and through the ejection ports 4. Each of the ejection ports 4 is a penetration hole formed in a plate member, and is formed as an elongated slit extending in a direction parallel to the direction of the rotation axis of the rollers 3 when seen from above. As a means to generate a high temperature air flow, a blower fan 21 and a rod-shaped heater 22 are provided. The blower fan 21, the heater 22 and the ejection ports 4 altogether constitute an air blowing mechanism which blows, from the side of the outer surface 1a of the belt 1, the hot air on the sheet S which is being conveyed.
The front surface of the sheet S which became wet in the printing process is heated by the hot air and the back surface of the sheet S is heated by the belt 1. In this manner, the ink is dried in an accelerated manner. Since the belt 1 is heated on its inner surface 1b by the heating unit 7 during operation of the apparatus, the belt 1 can keep a desired temperature during a long-time continuous printing. The desired temperature is in a range of between the lower limit permissive temperature for obtaining necessary drying performance (T-min) and the upper limit permissive temperature of resistance to heat of the sheet (T-max).
When a wide sheet S is used, it is possible that the hot air which is blown on a printed surface and has increased in humidity may stagnate in spaces between adjacent rollers 3 (i.e., spaces H of
The rollers 3, which are the pinch rollers, press the outer surface 1a of the belt 1 with predetermined urging force with the sheet S being held therebetween. When being pressed in this manner, the inner surface 1b of the belt 1 is pressed against the contact portion 5 of the heating unit 7, whereby the heat is efficiently transferred to the belt 1 from the contact surface 5a of the contact portion 5. If no roller 3 exists, clearance or an air layer may be easily formed between the inner surface 1b of the belt 1 and the contact surface 5a, and between the outer surface 1a of the belt 1 and the sheet S, whereby heat transfer to the back surface of the sheet S may become insufficient.
In the example of
This problem is solved by the varying arrangement of the gaps Δd in the direction of the rotation axis of the rollers 3 arranged in the sheet travelling direction as illustrated in
As the operating time of the apparatus is increased and the rotating time of the belt is also increased, the inner side of the belt 1 may be worn and slippage may be caused between the belt 1 and the rollers 3. Such slippage reduces the rotational speed of the belt 1 and, as a result, the sheet conveyance speed in the drying unit 51 becomes incorrect. In order to avoid this problem, it is desirable to prevent the wear of the belt 1 caused by the contact portion 5 as much as possible. Since the belt 1 is a flexible member, most of the wear occurs on the belt 1 in contact with the contact surface 5a of the contact portion 5. In order to reduce the wear of the belt 1, the contact frictional resistance should be lowered or the contact area should be reduced.
In order to lower the contact frictional resistance, a friction coefficient of the outer surface 1a of the belt 1 must be larger than those of the inner surface 1b and the contact surface 5a. For example, the friction coefficients of the inner surface 1b and the contact surface 5a (or the frictional resistance between the inner surface 1b and the contact surface 5a) preferably are 0.2 to 0.5. With such friction coefficients, the outer surface 1a of the belt 1 reliably holds the sheet S and the wear of the belt 1 due to contact friction between the inner surface 1b and the contact surface 5a is reduced.
In order to reduce the contact area, the area in which the contact surface 5a contacts the belt 1 should be reduced as much as possible. For example, as illustrated in
In addition, from the viewpoint of energy saving of the apparatus, power consumption in the heating element 6 of the heating unit 7 is preferably reduced. For example, as illustrated in
A behavior of change in a surface temperature of the sheet S in the drying unit 51 will be discussed. It is found that the surface temperature of the sheet S is increased in a stepped manner, not in a constant manner.
With such a behavior of the change in the surface temperature of the sheet S, the sheet S is sufficiently dried by agitating the air layer above the sheet S and remove the produced vapor without heating the sheet S with the heating unit 7 after the balance is lost. Thus, as illustrated in
According to the embodiment described above, the sheet S is dried with the hot air at the side of the outer surface of the belt 1 and, at the same time, is dried on the back surface thereof with the heat given from the inner surface 1b of the belt 1. In the drying process, the plurality of rollers 3 are pressed against the sheet S to enhance the contact between the outer surface 1a of the belt 1 and the sheet S, and between the inner surface 1b of the belt 1 and the contact surface 5a of the heating unit 7. With such close contact, the heat is transferred from the heating unit 7 to the sheet S via the belt 1 with high efficiency. In this manner, the sheet S can be dried reliably in high speed continuous printing and thus insufficient or uneven drying can be avoided.
Next, a second embodiment will be described. In high density printing, i.e., high-duty printing with a large amount of ink applied per unit area, it is possible that marks of divided small roller sections of rollers 3 as illustrated in
In the second embodiment, urging force for each of the small roller sections is determined independently such that each of the small roller sections apply the urging force suitable for reliable high speed conveyance of the sheet S without any severe deformation on the sheet surface.
In the first embodiment, a plurality of small roller sections are arranged in series on a rotation axis in each of the rollers 3 and these small roller sections are held collectively. In the second embodiment, however, each of small roller sections arranged in series is supported independently by a separate support mechanism. Among the small roller sections arranged in series as illustrated in
Each of the small roller sections 8 (8a, 8b) is constituted by bearings 9 (9a, 9b), shafts 10 (10a, 10b) and rollers 11 (11a, 11b). The shaft 10 is supported by two bearings 9 at both ends thereof and the bearings 9 are held by support members 13 (13a, 13b). The support members 13 (13a, 13b) are elastically supported on a plate member via separately-provided springs 12 (12a, 12b). Ejection ports 4 are formed on the plate member. The spring 12a and the spring 12b have different spring coefficients. Since the spring coefficients of the springs 12a and 12b are determined appropriately for the dimensions of the rollers 11a and 11b, the rollers 11a and 11b press the sheet S against a belt 1 uniformly with urging force. Since the urging force for each of the small roller sections is determined independently, any severe deformation of a surface of the sheet S or appearance of marks of the rollers on the sheet S can be avoided even in high density printing. In addition, the sheet S can be conveyed reliably at high speed. The rollers 11 may be formed of flexible rubber or foam or may have rounded corners. In this manner, appearance of the marks of the small roller sections in high density printing may further be reduced.
The rollers disposed alternately along the sheet travelling direction have spring coefficients different from one another. In particular, the rollers disposed in the upstream of the sheet travelling direction have smaller spring coefficients than the rollers disposed in the downstream. The reason for this is as follows.
As the sheet S after being subject to high density printing travels toward the downstream in the drying unit 51, an amount of curling in the sheet S increases. As a result, the curled sheet S may be caught in arbitrary roller 11 and may cause a conveyance jam. In order to avoid this phenomenon, the rollers are pressed against the belt 1, i.e., the sheet S, with relatively small urging force in the upstream side (which corresponds to a sheet introduction side) of the sheet travelling direction so as to protect the sheet S that has a high moisture content and is thus vulnerable to marks on the surface thereof. In the downstream side (which corresponds to a sheet discharge side) of the sheet travelling direction, the sheet S is pressed against the belt 1 by the rollers with the urging force larger than that of the rollers in the upstream side, whereby curling of the sheet S caused as the sheet S dries is reduced. As described above, since the rollers are provided with different urging force, i.e., the first roller in the upstream has smaller urging force than that of the second roller in the downstream, curling of the sheet S can be prevented while appearance of the marks of the small roller sections can be avoided.
Although all the small roller sections are supported independently in the above structure, some of the adjacent small roller sections may be supported by a common rotation axis along the direction of the rotation axis. Alternatively, a plurality of small roller sections may be supported integrally along the direction of the rotation axis and the first roller in the upstream has smaller urging force than that of the second roller in the downstream in the sheet travelling direction.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2010-002102 filed Jan. 7, 2010, which is hereby incorporated by reference herein in its entirety.
Number | Date | Country | Kind |
---|---|---|---|
2010-002102 | Jan 2010 | JP | national |
Number | Name | Date | Kind |
---|---|---|---|
3800432 | Miyata et al. | Apr 1974 | A |
4973824 | Ohashi et al. | Nov 1990 | A |
6336722 | Wotton et al. | Jan 2002 | B1 |
6582072 | Wotton et al. | Jun 2003 | B1 |
7077584 | Yoshida | Jul 2006 | B2 |
Number | Date | Country |
---|---|---|
2657571 | Sep 1997 | JP |
Number | Date | Country | |
---|---|---|---|
20110164101 A1 | Jul 2011 | US |