Electro-photography (EP) printing devices form images on print media by placing a uniform electrostatic charge on a photoreceptor and then selectively discharging the photoreceptor in correspondence with the images. The selective discharging forms a latent electrostatic image on the photoreceptor. Colorant is then developed onto the latent image of the photoreceptor, and the colorant is ultimately transferred to the media to form the image on the medium. In dry EP (DEP) printing devices, toner is used as the colorant, and it is received by the media as the media passes below the photoreceptor. The toner is then fixed in place as it passes through heated pressure rollers. In liquid EP (LEP) printing devices, ink is used as the colorant instead of toner. In LEP devices, an ink image developed on the photoreceptor is offset to an image transfer element, where it is heated until the solvent evaporates and the resinous colorants melt. This image layer is then transferred to the surface of the print media being supported on a rotating impression drum.
Non-productive print cycles may be used during various stages of the print process. During non-productive print cycles, images are not being written to the photoreceptor or transferred to the image transfer element. The lack of image transfers during such non-productive cycles can damage the image transfer element and reduce print quality.
Various examples are described herein with reference to the accompanying drawings, in which:
The following description provides illustrative examples of an apparatus and printing process associated with an LEP printing process. The examples however are presented for the purpose of illustration rather than limitation, and may therefore be applicable to printing processes other than the LEP printing process described below.
An LEP printing press 100 includes a print engine 102 that receives a print substrate, illustrated as print medium 104 (e.g., cut-sheet paper) from a media input mechanism 106. After the printing process is complete, the print engine 102 outputs the printed medium 108 to a medium output mechanism, such as a medium stacker tray 110. The printing process is generally controlled by a print controller 120 to generate the printed medium 108 using digital image data that represents words, pages, text, and images that can be created, for example, using electronic layout and/or desktop publishing programs. Digital image data is generally formatted as one or multiple print jobs that are stored and executed on the print controller 120, as further discussed below with reference to
The print engine 102 includes a photo imaging component, such as a photoreceptor 112 mounted on a photoreceptor/imaging drum/cylinder 114. The photoreceptor 112 defines an outer surface of the imaging drum 114 on which images can be formed. The photoreceptor 112 may coated onto the imaging drum 114, or it may be provided by foil wrapped around the drum 114. A charging component such as charge roller 116 generates electrical charge that flows toward the photoreceptor surface and covers it with a uniform electrostatic charge. The print controller 120 uses digital image print data and other inputs such as print job and print media parameters, temperatures, and so on, to control a writing head, in this case laser imaging unit 118, to selectively expose the photoreceptor 112 in a pattern consistent with the digital image print data. The laser imaging unit 118 exposes image areas on the photoreceptor 112 by dissipating (neutralising) the charge in those areas. Exposure of the photoreceptor in this manner creates a ‘latent image’ in the form of an invisible electrostatic charge pattern that replicates the image to be printed.
In LEP, the printing process may comprise three transfers of ink, referred to as zero, first and second transfers. The zero transfer is from an ink developer, ID, 122 to the photoreceptor 112. The first transfer is from the photoreceptor 112 to an ITM drum 126. The second transfer is from the ITM drum 126 to the IMP drum 128 on which a substrate such as a print medium 104 mounted.
In the zero image transfer, after the latent electrostatic image is formed on the photoreceptor 112, the image is developed thereon by engaging an ID 122 containing charged liquid ink of an appropriate colour to develop ink onto the latent electrostatic image on the photoreceptor 112 and form an ink image on the outer surface of the photoreceptor 112.
In the zero transfer, the ID 122 performs three functions: ink development, ink transfer to the photoreceptor 112 and residual ink removal. Each ID 122 includes several components including rollers and electrodes and to which specific voltages are applied to perform these functions. Ink in an ID inlet flows through a gap between the two parts of an electrode until it reaches an ID developer roller. The developer roller within the ID 122 is coated with a layer of charged liquid ink particles and the developer roller engages the surface of the photoreceptor and develops in onto it. Print controller 120 can apply printing voltages 140 from a voltage source 136 to an ID 122 through controlling a voltage application mechanism 142 such as a switch, to differentially charge the electrodes, surfaces and rollers in the ID to voltages, collectively referred to herein as “printing voltages”, to create the electric fields between the ID and photoreceptor that enable the development of charged ink from the ID 122 to the latent electrostatic image on the photoreceptor 112. In printing a colour separation, the developer roller is at a voltage level in between the maximum and minimum voltage of the photoreceptor 112, and as the developer roller and photoreceptor 112 rotate against one another, different portions of the charged ink layer progressively come into contact with the photoreceptor 112 at a nip between the two rollers. Charged ink on the developer roller is attracted to locations on the photoreceptor 112 where surface charge has been neutralized by the laser, and repelled from locations on the photoreceptor 112 where surface charge has not been neutralised by the laser. This initial transfer of ink from the ID to the photoreceptor 112 that produces a developed ink image on the surface of the photoreceptor 112 is referred to as the ‘zero’ image transfer. Afterwards, to perform the cleaning function, a cleaner roller cleans residual ink off of ID rollers that does not transfer to the photoreceptor.
Each ID 122 develops one ink colour of the image, and each developed colour corresponds with one image impression or colour printing separation. In an example, the print controller 120, described in more detail below in relation to
In the example, in a subsequent ‘first’ image transfer, the single colour separation impression of the ink image developed on the photoreceptor 112 is transferred from the photoreceptor 112 to an image transfer blanket 124. The image transfer blanket 124 is primarily referred to herein as the print blanket 124 or blanket 124. The print blanket 124 is wrapped around and securely fastened to the outer surface of the intermediate transfer member (ITM) drum 126. The first image transfer that transfers ink from the photoreceptor 112 to the print blanket 124 is driven by an applied mechanical pressure between the imaging drum 114 and the ITM drum 126, and electrophoresis of the electrically charged ink particles. The electric field that drives the ink transfer is created by a bias voltage applied to the print blanket 124. Both the blanket bias voltage and the mechanical pressure between the imaging drum 114 and ITM drum 126 can impact the image transfer quality.
The print blanket 124 may be heated by both internal and external heating sources such as infrared heating lamps (not shown). The heated print blanket 124 causes most of the carrier liquid and solvents in the transferred ink image to evaporate. The heated blanket 124 also causes the solid particles in the ink to partially melt and blend together. This results in a finished ink image on the blanket 124 in the form of a hot, nearly dry, tacky plastic ink film.
In the example, in a ‘second’ image transfer, this hot ink film image impression is then transferred from the blanket 124 to a substrate such as a sheet of print media 104 (e.g., sheet or web paper), which is held or supported by an impression (IMP) drum/cylinder 128. Contact pressure between the ITM drum 126 and IMP drum 128 compresses the blanket 124 against the print media 104 to facilitate the transfer of the hot ink film image. The temperature of the print media 104 is below the melting temperature of the ink particles, and as the ITM drum 126 and IMP drum 128 rotate against one another under pressure, the hot ink film comes into contact with the cooler print medium 104 and causes the ink film to solidify and peel off from the blanket 124 onto the print medium 104.
This process is repeated for each colour separation in the image. In a 4-shot printing process, the colours accumulate in successive revolutions on the print media 104 wrapped on the impression drum 128 until all the colour separation impressions (e.g., C, M, Y, and K) in the image are transferred to the print media 104. After all the colour impressions have been transferred to the sheet of print media 104, the printed media 108 sheet is transported by various rollers 132 from the impression drum 128 to the output mechanism 110. In a 1-shot printing process, the colour separations accumulate on the print blanket 124 and are transferred to the print media at one time after all the colour separations have been transferred to the blanket.
As described above, the colour printing separations represent productive print cycles in which an ID 122 is engaged with the imaging drum 114 and has printing voltages from printing voltage source 140 applied thereto by voltage application mechanism 142, and in which a latent image is formed on the photoreceptor 112 so as to cause ink to be developed from the engaged ID 122 onto the photoreceptor 112 for transfer on to the print media 104.
In examples, the printing device 100 may in certain circumstances perform non-productive, empty separation printing cycles during the printing process for various reasons. Empty separations are printed under substantially the same printing conditions as a regular or ‘colour’ printing separation which includes ink transfer, the main difference is that, in empty separation print cycles, no image is created on the photoreceptor 112 and substantially no ink is transferred thereto. One reason an empty separation may be used is that an extra drying cycle can be used for the ink to dry before transferring it to the substrate. A second reason an empty separation is used is to, in certain circumstances, heat the substrate, the substrate may be provided on the IMP drum 128 for at least one cycle to heat it while it is on an IMP drum 128 before the ink transfer begins. A third reason an empty separation may be used is to delay a transfer, for example transferring to a conductive substrate where it may in certain cases be necessary to turn off the high-voltage on the ITM drum 126. There may be further reasons why empty separation printing is used.
If, during empty separations, the voltage applied to the ID 122 is the same as for printing separations (i.e. from printing voltages 140 source), a small amount of ink is still developed on the ID developer roller. Although no image exists on the photoreceptor 112, some ink is still transferred to the photoreceptor 112 from the ID 122, this is called background. During an empty separation therefore, there is background transfer which is undesirable due to ink consumption and possible print quality side effects. There is also imaging oil transfer from the ID 122 to the photoreceptor 112 which is for keeping the blanket wet, minimising current during transfer from the imaging drum 114 to ITM drum 126 and avoiding back transfer from the blanket to the photoreceptor 112. Dropping the developer roller voltage to zero during an empty separation is not desirable however due to the time for an ID 122 to reach the set voltage.
If instead selected empty separation voltages 138 provided by voltage source 136 are applied to the ID 122 for empty separations, substantially no ink is developed on the developer roller and therefore substantially no background transferred between the ID 122 and photoreceptor 112.
Voltage source 136 is thus intended to represent a plurality of sources that provide individual voltages to the ID for differentially electrically charging surfaces and several rollers within the ID, including at printing voltages 140 or empty separation voltages 138. Accordingly, the voltage application mechanism 142 can include a plurality of application mechanisms suitable for applying individual voltages within the ID. For example, voltage application mechanism 142 may accommodate differences in timing while changing the individual voltages within the ID when transitioning back and forth between colour printing separation voltages 140 and empty separation voltages 138.
Selected empty separation voltages are different from printing voltages and therefore transitions from printing to empty separation voltages and vice versa exist. Transitions from empty separation voltages to printing separations however cannot easily be performed in the time between consecutive separations. This is because, to achieve good print quality, the printing voltages are to be prepared and stabilised in a sufficient amount of time before printing. To make the transition from empty separation voltages to printing voltages, firstly the empty separation voltages may be turned off on the ID 122 or the voltages applied to the ID 122 changed such that the printing voltages can be built up on the ID 122. Where there is a time constraint in modifying the voltage of the ID 122 in this way, this can create difficulties with achieving a desired print quality. In practice, there are circumstances in which these time constraints can arise.
For example, Yellow-Magenta-Cyan-Black-White-White printing (YMCKWW) (also referred to as ‘White-White’ printing) is a common colour separation order in labels & packaging. The white ink transferred to the substrate may be desirably of a high opacity and therefore a repetition of the white ink transfer may be performed to achieve such a high opacity. However, a special drying policy may be advisable in these circumstances to avoid print quality issues such as cracks and wetness. This drying policy may use an empty separation before and after printing a white separation, furthermore this empty separation should be performed by an available ID other than white. During white-white printing, a yellow ID is generally selected as its background is the least visible. As described above, it may be desirable to use different voltages for empty separations to substantially eliminate the background, but by doing so the use of a yellow ink developer for the empty separation may cause difficulties because two consecutive spreads would look like YMCKY′WY′WY′-YMCKYWY′WY′ (where Y′ is an empty separation). This would result in Y′-Y printing, i.e. consecutive empty separation printing and then colour separation printing using the same yellow ID. This creates a time constraint in modifying the voltage of the ID 122 from the empty separation voltages to printing voltages and this would unfeasible without inserting extra null cycles to allow sufficient time for the ID to transition from the empty separation voltage to be ready to perform printing separations. Inserting extra dry null cycle harms utilisation and has a negative impact on the life span of consumables. A similar time constraint may also arise when performing ‘pre’-empty separations and ‘post’-empty separations using a Yellow ID in YMCK printing.
An example print controller 120 for addressing this will now be described in more detail with reference to
The RAM 220 comprises a digital front end (DFE) 222, coupled to an imaging unit 224. The DFE 222 comprises a memory to store printing jobs. The imaging unit 224 is also coupled to the ordering unit 226. The ordering unit 226 is further coupled the paper control node 228 and main control node 229.
After raster image processing is performed, print jobs are stored in the DFE 222 and ready to be sent for printing. A print job comprises the print data regarding the image to be printed. The imaging unit 224 takes at least one job from the DFE 222, retrieves information spread by spread, imposes constraints, such as empty separations and image placement. Each spread comprises a plurality of colour separations. This information is then sent to the ordering unit 226 to create the right ordering, before sending this information to the MCN 229. In sheet-fed presses, as opposed to web-fed machines, the ordering in sheet-fed presses is performed by the Paper Control Node (PCN) 228.
The print controller 120, or one or more components thereof, may be implemented purely in either software or hardware, or furthermore a combination of the two. It should also be appreciated that the print controller does not have to reside inside the printing device 100, and may be located externally but in communication with the printing device.
The print controller 120, or one or more components thereof operating individually or in combination, is provided to, in use, monitor an order of colour separations to be printed onto the print medium and detect in the order of colour separations an empty separation of an ID followed by a printing separation of the same ID. In response to the detection, the print controller 120, or one or more components thereof operating individually or in combination, is provided to replace in the order of the colour separations the ID for the empty separation with a different ID. The print controller 120 thus operates to ensure that the print engine 102, when performing non-productive empty separation print cycles with an ID at an empty separation voltage different to a print voltage for a productive print cycle, is not followed immediately by a colour separation using the same ID that was used in the preceding empty separation. This will now be described in more detail with reference to examples.
An example process of selecting an ID for use in an empty separation in accordance with examples of the present disclosure will now be described in more detail with reference to
In 304, the print controllers detects if in the order of colour separations an empty separation of an ID followed by a printing separation of the same ID, an empty separation representing a separation in which no image is formed on the photoreceptor and the ID is engaged at a different voltage than in the printing separation. This is to in the empty separation substantially wet the photoreceptor and substantially not transfer ink thereto. If this is not detected, the print controller continues to monitor the order of colour separations in 302.
If in 304, it is detected that there is an empty separation followed by a printing separation of the same ID, the print controller proceeds to 306. In 306, the print controller replaces in the order of colour separations the ID for the empty separation with a different ID. In examples, the selection of an ID for use in an empty separation may be dependent on the time period for stabilising a voltage of an ID from the empty separation voltage to the colour separation voltage.
Therefore, in the examples given in
Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2016/060320 | 5/9/2016 | WO | 00 |
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WO2017/194086 | 11/16/2017 | WO | A |
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20190033744 A1 | Jan 2019 | US |