Patent Application
20100302331
This disclosure relates to media handling systems, and more specifically, to an improved apparatus for flattening corrugated media passing through the print zone of an ink jet printer.
Flexographic printing as shown, for example, in U.S. Pat. No. 7,486,420 is the major process used to print packaging materials. Flexography is used to print corrugated containers, folding cartons, corrugated board displays, multiwall sacks, paper sacks, plastic bags, milk cartons, disposable cups and containers, labels, etc. In the typical flexographic printing sequence, the substrate is fed into a press from a roll or pre-cut board. The image is printed as the substrate is pulled through a series of flexographic cylinders, or stations, or print units. Each print unit is printing a single color. Unlike traditional cylinder based ink transfer technologies for printing of corrugated materials, such as Flexography, digital ink jet printing requires that the corrugated media be held flat and be precisely spaced from the print head plane throughout the entire print zone. Depths of Focus (DoF) gaps of the order of 1.0±0.2 mm are typical and they are difficult to achieve and maintain across a large area. Variations in this critical gap cause Time of Flight errors in pixel placement onto the moving media and degrade image quality. Since corrugated material is quite stiff any residual curl in boards of the material is difficult to suppress over a large area. In digital ink jet printing of corrugated material, the print zone area is measured in square feet and not a narrow band of a few square inches as with a Flexographic cylinder. Suppressing the curl and holding the corrugated boards flat is a challenge. If the curl is concaved toward the print heads no amount of vacuum can ever flatten the edges. If the curl is concaved away from the print heads, then a vacuum transport can suppress the ‘hump’ if pressure is adequate. Although friction may fight ‘flattening out’ the curl on a large board once the edges are tacked to the transport belt. Any such ‘long wave length/low frequency error’ will produce image defects such as bowed lines in the cross process direction.
In answer to these problems and disclosed herein is the use of a series of low wetting star wheels positioned between staggered ink jet print heads to flatten corrugated media in conjunction with a vacuum transport belt and an acquisition cylinder to iron the curl out of the corrugated media in both the process and cross process directions.
Various of the above-mentioned and further features and advantages will be apparent to those skilled in the art from the specific apparatus and its operation or methods described in the example(s) below, and the claims. Thus, they will be better understood from this description of these specific embodiment(s), including the drawing figures (which are approximately to scale) wherein:
While the disclosure will be described hereinafter in connection with a preferred embodiment thereof, it will be understood that limiting the disclosure to that embodiment is not intended. On the contrary, it is intended to cover all alternatives, modifications and equivalents as may be included within the spirit and scope of the disclosure as defined by the appended claims.
The disclosure will now be described by reference to a preferred embodiment ink jet printing apparatus that includes a method and apparatus that flattens corrugated boards during transport through a printing zone.
For a general understanding of the features of the disclosure, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to identify identical elements.
Referring now to printer 10 in
The recording section adjacent the recording head includes an endless conveyor belt 20 that includes a number of small holes (not shown) therein and wound around a drive roller 22B disposed downstream in the paper conveyance direction A and a driven roller 22A disposed upstream in the paper conveyance direction A. The conveyor belt 20, which could be woven and/or porous, etc., is configured such that it is circulatingly driven by the drive and driven rollers. A vacuum plenum 40 is connected through conduit 42 to a vacuum source 41 and adapted to apply vacuum pressure to the holes in conveyor belt 20 in order to attach corrugated board 18 to the belt 20 sliding across the vacuum platen 30 during recording by the recording head 14.
The ink jet recording head 14 faces a flat portion of the conveyance belt 20 and this facing area serves as an ejection area to which ink droplets are ejected from the ink jet recording head 14. The corrugated board 18 is retained by the conveyor belt 20 and transported through the ejection region, where the ink droplets corresponding to an image are ejected from ink jet recording head 14 and onto the board 18 in a state where the board 18 faces the ink jet recording head 14.
In order to maintain image quality and DoF between recording head 14 and corrugated boards beneath the recording head and in accordance with the present disclosure as shown in
Star wheels 50 as shown in
It should now be understood that a solution for low frequency DoF control errors in ink jet printing onto corrugated media has been disclosed that includes employing a vacuum transport in combination with an acquisition cylinder positioned shortly before corrugated media reaches a series of staggered ink jet print head modules and star wheels distributed about and positioned between the staggered ink jet print head modules and protruding below the staggered print head modules to flatten corrugated media and thereby improve image quality.
The claims, as originally presented and as they may be amended, encompass variations, alternatives, modifications, improvements, equivalents, and substantial equivalents of the embodiments and teachings disclosed herein, including those that are presently unforeseen or unappreciated, and that, for example, may arise from applicants/patentees and others. Unless specifically recited in a claim, steps or components of claims should not be implied or imported from the specification or any other claims as to any particular order, number, position, size, shape, angle, color, or material.
