A printer may apply print agents to a paper or another substrate. One example of a printer is a Liquid Electro-Photographic (“LEP”) printer, which may be used to print using fluid print agents such as an electrostatic printing fluids. Such electrostatic printing fluids may include electrostatically charged or chargeable polymeric particles (for example, resin or toner particles) dispersed or suspended in a carrier fluid.
In an example of printing, a LEP printer may form an image on a print substrate by placing an electrostatic charge on a photoconductive surface, and then utilizing a laser or other light scanning unit to apply an electrostatic pattern of the desired image on the photoconductive surface to selectively discharge the photoconductive surface. The selective discharging forms a latent electrostatic image on the photoconductive surface. The printer includes a developer assembly to develop the latent image into a visible image by applying a thin layer of polymeric electrostatic ink (which may be generally referred to as “LEP ink” or “electronic ink” in some examples) to the patterned photoconductive surface. Charged particles (sometimes referred to herein as “ink particles” or “colorant particles”) in the LEP ink adhere to the electrostatic pattern on the photoconductive surface to form an inked image. In examples, the inked image, including colorant particles and a carrier fluid, is transferred utilizing a combination of heat and pressure from the photoconductive surface to an intermediate transfer member (“ITM”) attached to, or incorporated in, an ITM drum or ITM belt. The ITM is heated until carrier fluid evaporates and colorant particles melt. A resulting molten film representative of the image is then applied to the surface of the print substrate via pressure and tackiness. In examples the ITM that is attached to or incorporated within the ITM drum or ITM belt is a consumable or replaceable ITM. For printing with colored LEP inks, the printer may include a separate developer assembly for each of the various colored inks.
A key process in LEP printing is the drying of the ink to form a molten film, and the application of the molten film to the heated ITM. Carrier fluid (e.g., an imaging oil) is evaporated from the LEP ink by virtue of applying heating and air flow adjacent to the ITM. The vapor from this evaporation process contains a high amount of imaging oil. In certain circumstances, if the imaging oil/air mixture is not sufficiently diluted or removed from the printer, ignition and explosion could occur. In some examples insufficient dilution or removal may be the result of an airpath for the imaging oil/air mixture becoming blocked (e.g., blocked by paper, dust, mechanical deformation). In other examples, insufficient dilution or removal may be the result of malfunction of a system component (e.g., a fan, a condenser, or a vacuum element).
One method for avoiding ignition of carrier fluid vapor and potential explosion at a printer is to mix this air with at least 4 times as much fresh air as needed (to reach ¼ Lower Explosion Limit) in an evaporation zone. Another method for avoiding ignition of carrier fluid vapor and potential explosion is to cause the oil-containing air to cross a short, small-volume, evaporation zone, and then cause the oil-containing air to be pulled through a condenser unit for distillation and cooling. A safety control for both methods has been to utilize pressure gauges or flow gauges situated at various points in the carrier fluid evaporation zone to monitor the flow of the oil/air mixture. Such pressure and flow gauges can be complex and delicate, prompting frequent accuracy verification procedures and expensive replacements.
To address these issues, various examples described in detail below provide a system and method for identification of gas conveyance malfunctions utilizing temperature readings. As depicted in
As used herein, a “channel” refers generally to a passageway. In examples a channel may be partially enclosed by structural elements, e.g., a channel between two structural elements. In other examples, a channel may fully enclosed, e.g., as a channel through a tube or pipe. As used herein a first component being in “fluid connection with” or “fluidly connected to” a second component refers generally to the first and second components being connected in a manner such that a fluid is enabled to flow from the first to the second component, or the reverse.
The heat blower 104 is to heat the subject gas, and to cause the subject gas to move through the channel towards the condenser 104. As used herein, a “heat blower” refers generally to an electromechanical device for providing a heated airflow through an outlet. In examples, the heat blower may be a heated air knife capable of providing through an outlet a heated air flow between 60 m/s and 400 m/s, at temperatures between 110 C and 220 C.
As used herein, a “condenser” refers generally to any component for cooling a hot gas or vapor to a liquid form. In examples, the condenser may include tubing arranged to traverse a core. In examples, the tubing defines a pathway for a cooling fluid (e.g., water), with passage of the subject gas across the tubing causing a cooling of the subject gas. As used herein, a “core” refers generally to an assembly of connected and/or fluidly connected components. In an example, the core of a condenser may include a gas flow inlet, a set of cooling fins, and a gas flow outlet. In examples, the cooling fins, the flow inlet and/or the gas flow outlet may be constructed of a metal, e.g., aluminum, copper, or steel. In other examples, the cooling fins, the gas flow inlet and/or the gas flow outlet may be constructed of a plastic that is capable of withstanding high temperatures, e.g., up to 1700 C.
Continuing at
The system includes a controller 110 operatively connected to the temperature sensor set 108. As used here, a “controller” represents the processing and memory resources and the programming, electronic circuitry and components needed to control the operative elements of the system 100. Controller 110 may include distinct control elements for individual system components.
The controller 110 is to identify a malfunction event for the heat blower 104, the condenser 106, and or the channel 102 based upon a comparison of a temperature reading to a predetermined threshold temperature. As used herein, a “malfunction event” or “malfunction” refers generally to a failure to function in a normal or prescribed manner. In a particular example, a malfunction is a failure to function according to a specification.
In examples, the controller is to initiate a recovery action from a set of applicable recovery actions based upon the identified malfunction event. In examples, the controller identifying the malfunction event and/or initiating the recovery event may include the controller accessing predetermined threshold temperatures, historical temperature measurements, historical component malfunction data, and other information in a look up table or other database. In other examples, the controller identifying the malfunction event and/or initiating the recovery event may include the controller accessing one or more of a dynamic database, a neural network, or a machine learning application to access predetermined threshold temperatures, historical temperature measurements, historical component malfunction data, and other information.
Moving to
In this manner the disclosed apparatus and method enable the utilization of simple, inexpensive, and robust temperature sensors to identify malfunctions in system for identification of gas conveyance malfunctions. In a particular example, the disclosed apparatus and method enable detection of malfunctions relating to potentially harmful vapor outflows in a carrier fluid evaporation zone of a LEP printer. Users and providers of LEP printers, and other systems (e.g., any system that includes components for heating and moving a potentially volatile subject gas), will appreciate the safety, system reliability and cost benefits afforded by the disclosure. Installations and utilization of LEP printers and other systems that incorporate the disclosed apparatus and/or method should thereby be enhanced.
In this example, the system 100 includes a heat blower 104 positioned adjacent to and in fluid connection with the first channel 102 to heat the subject gas. The heat blower 104 includes an outlet 308 extended from the heat blower to form a second junction 318 with the first channel 102. The heat blower 104 and its outlet 308 are positioned to cause the subject gas to move through the first channel 102 towards the condenser 106 situated within the second channel 212. In this example the outlet 308 is a slit outlet, such that there is no element of the heat blower 104 or the outlet protruding in the first channel 102. In other examples, the heat blower 104 may include a nozzle, e.g., a nozzle that extends into the channel.
In this example, the system 100 includes a negative pressure component 214 that is positioned so as be operatively connected to the second channel 212 and cause the subject gas to move through the second channel 212 and through the condenser 106.
Continuing at
In the example shown in
A first temperature sensor 108a is positioned adjacent to an end opening 310 of the first channel 102 that is closer to the heat blower 104 than to the first junction 304. The processing resource 370 on the controller 110 executing control instructions 360 is to is to identify a malfunction event for the heat blower 104 or the first channel 102 based upon a comparison of a temperature reading of the subject gas taken by the first temperature sensor 108a to a threshold temperature. In an example, controller 110 is to identify the malfunction event based upon a determination the temperature reading exceeds the threshold temperature. In an example, the identified malfunction event may be that the first channel 102 is blocked between the heat blower 104 and the first junction 304. In another example, the identified malfunction event may be that the heat blower 104 is malfunctioning (e.g., the heat blower 104 is bent and thereby pushing heated air 332 in a direction other than an intended direction 336 that is towards the first junction 304 and the second channel 212).
Continuing at
A third temperature sensor 108c is situated in the second channel 212 downstream of an outlet 320 of the condenser 106. The processing resource 370 on the controller 110 executing control instructions 360 is to identify a malfunction event for the condenser 106 based upon a comparison of a temperature reading of the subject gas taken by the third temperature sensor 108c with a threshold temperature. In an example, controller 110 is to identify the malfunction event based upon a determination the temperature reading exceeds the threshold temperature. In an example, the identified malfunction event may be a that a cold-water supply to the condenser, or another chilling property or function of the condenser 106, is insufficient.
A fourth temperature sensor 108d is positioned adjacent to an end opening 314 of the first channel 102 that is located on an opposite side of the first junction 304 relative to the outlet 308 of the heat blower 104. The processing resource 370 on the controller 110 executing control instructions 360 is to identify a malfunction event for the negative pressure component 214 or the first channel 102 based upon the comparison with a threshold temperature. In an example, controller 110 is to identify the malfunction event based upon a determination the temperature reading exceeds the threshold temperature. In an example, the identified malfunction event may be that heated gas (e.g., hot air containing oil vapor) is escaping from the first channel 102 through the second end opening 314, rather than moving efficiently through the second channel 212 and the condenser 106. In an example, the identified malfunction event may be that the second channel 212 is at least partially blocked, e.g., blocked between the inlet 312 to the condenser 106 and the outlet 308 of the condenser. In another example, the identified malfunction event may be that the negative pressure component 214 is not providing enough suction.
Continuing at
It should be noted that while in the example discussed above with respect
The system 100 includes a cover 404 for a heat source 418 (e.g., a set of heat lamps) positioned opposite a face 402a of the ITM belt 402. In examples, the cover 404 be constructed of, or include, one from the set of a metal, a plastic, a glass, and any other heat-tolerant medium.
The system 100 includes a first channel 102 situated to convey a subject gas, with the first channel 102 being formed in part by the face 402a of the ITM belt 402. In this example, the subject gas is or includes a potentially volatile vapor that is created when the heat source 418, in combination with the forced hot air provided from an outlet 308 of the hot air knife 104, evaporates carrier fluid residue on present on the face 402a of the ITM belt 402. In an example, the carrier fluid is an isoparaffinic hydrocarbon solvent carrier fluid.
Continuing at
The negative pressure component 214 is operatively connected to the second channel 212 to cause the subject gas to move through the second channel 212 and the condenser situated within the second channel 212. The system 100 includes a set of temperature sensors 108-108d situated to take a set of temperature readings of the subject gas within, or adjacent, to the first and second channels 102212.
In the example of
Continuing at
The processing resource 370 on the controller 110 executing control instructions 360 is to control the heated air knife 104 and the negative pressure component 106 to regulate heating and movement of the subject gas through an evaporation path (designated with a dotted pattern 406 in
In an example the target gas velocity for the subject gas to travel through the evaporation path 406 is a safety margin velocity at least 3 times the flame propagation velocity for an evaporated isoparaffinic hydrocarbon solvent. As used herein, “flame propagation velocity” is used synonymously with “flame speed” and refers generally to a rate of expansion of a flame front in a combustion reaction. In this manner, a self-sustained fire or flame in the evaporation path 406 is avoided.
Continuing at
The first temperature sensor 108a is positioned adjacent to an end opening 310 of the first channel 102 that is closer to the outlet 308 of the heat blower 104 than to the first junction 304. The processing resource 370 on the controller 110 executing control instructions 360 is to identify a malfunction event for the heat blower 104 or the first channel 102 based upon a comparison of a temperature reading of the subject gas taken by the first temperature sensor 108a to a threshold temperature. In an example, controller 110 is to identify the malfunction event based upon a determination the temperature reading is above a threshold temperature between 45 and 55 degrees C. In a particular example, the threshold is 50 degrees C.
A second temperature sensor 108b is positioned in the second channel 212 between the first junction 304 and an inlet 312 to the condenser 106.
The processing resource 370 on the controller 110 executing control instructions 360 is to identify a malfunction event for the heat blower 104 or the first channel 102 based upon a comparison of a temperature reading of the subject gas taken by the second temperature sensor 108b with a threshold temperature.
In an example, controller 110 is to identify the malfunction event based upon a determination the temperature reading is below a threshold temperature between 90 and 110 degrees C. In a particular example, the threshold is 100 degrees C.
A third temperature sensor 108c is situated in the second channel 212 downstream of an outlet 320 of the condenser 106. The processing resource 370 on the controller 110 executing control instructions 360 is to identify a malfunction event for the condenser 106 based upon a comparison of a temperature reading of the subject gas taken by the third temperature sensor 108c with a threshold temperature. In an example, controller 110 is to identify the malfunction event based upon a determination the temperature reading exceeds the threshold temperature between 15 and 25 degrees C. In a particular example, the threshold is 20 degrees C.
Continuing at
After the controller 110 identifies the malfunction event for the heat blower 104, the condenser 106, the first channel 102, and/or the second channel 212, in examples the processing resource 370 on the controller 110 executing control instructions 360 is to initiate a recovery action.
According to the example LEP printer of
The charging elements 504a 504b may each be or include a charge roller, corona wire, scorotron, or any other charging device. In examples, a uniform static charge is deposited on the photoconductive surface 802 by the charging element 804.
Continuing at
A set of developer assemblies 510a 510b is disposed adjacent to each the photoconductive surfaces 502a 502b and may correspond to various LEP ink colors such as cyan, magenta, yellow, black, a custom spot color, and the like. There may be one developer assembly for each ink color. In other examples, e.g., black and white printing, a single developer assembly may be included in LEP printer 400. During printing, the appropriate developer assembly 510a 510b is engaged with the respective photoconductive surface 502a 502b. The engaged developer assemblies present a uniform film of LEP ink to the photoconductive surfaces 502a 502b. The ink contains electrically charged pigment particles which are attracted to the opposing charges on the image areas of the photoconductive surfaces 502a 502b. As a result, each photoconductive surface 502a 502b has a developed image on its surface, i.e., a pattern of ink corresponding with the electrostatic charge pattern (also sometimes referred to as a “separation”).
Continuing with the example of
Once the layers of LEP ink have been transferred to the face 402a of the ITM belt 402a (via the “first transfer” from each of the photoconductive surfaces 502a 502b), the layers are next transferred to a print substrate 520. In this example, print substrate 520 is a web substrate moving along a substrate path in a first substrate path direction 522a, and then in a second substrate path direction 522b. In other examples, the print substrate may a sheet substrate that travels along a substrate path. This transfer from the face 402a of the ITM belt 402 to the print substrate 520 may be deemed the “second transfer”, which takes place at a point of engagement between the face 402a of the ITM belt 402 and the print substrate 520. The impression cylinder 508 can both mechanically compress the print substrate 520 into contact with the face 402a of the ITM belt 402 and also help feed the print substrate 520.
Continuing with the example of
A negative pressure component, positioned in fluid connection with the second channel, is to cause the subject gas to move through a portion of the first channel and through the condenser (block 604). Referring back to
A set of temperature sensors positioned within, or adjacent to an end opening of, the first channel and/or the second channel are utilized to take temperature readings (block 606). Referring back to
A malfunction event for at least one from the set of the heat blower, the first channel, the second channel, the condenser, and the negative pressure component is identified based upon a comparison of the set of temperature readings to a set of threshold temperatures (block 608). Referring back to
A recovery action for the identified malfunction event is initiated (block 610). Referring back to
The example of
A recovery action for the identified malfunction event is initiated. The recovery action includes at least one from the set of: increasing or decreasing a heating or a flow of the heat blower; increasing or decreasing suction created by the negative pressure component; increasing or decreasing a chilling or a flow of the condenser; causing sending of malfunction remedy instructions to a user interface; initiating a calibration routine; and causing an automatic shutdown of an apparatus that incorporates the first and second channels (block 710). Referring back to
Although the flow diagrams of
It is appreciated that the previous description of the disclosed examples is provided to enable any person skilled in the art to make or use the present disclosure. Various modifications to these examples will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other examples without departing from the spirit or scope of the disclosure. Thus, the present disclosure is not intended to be limited to the examples shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the blocks or stages of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features, blocks and/or stages are mutually exclusive. The terms “first”, “second”, “third” and so on in the claims merely distinguish different elements and, unless otherwise stated, are not to be specifically associated with a particular order or particular numbering of elements in the disclosure.
Filing Document | Filing Date | Country | Kind |
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PCT/US2021/057075 | 10/28/2021 | WO |