Patent Grant
8789925
This disclosure relates generally to methods for forming ink images on a substrate and, more particularly, to using a printer in a process for printing images with a magnetic ink on paper or another porous substrate.
Inkjet imaging devices are used to print a wide range of documents using various types and colors of ink. Some printed documents are read by both humans and by other machines. For example, a check includes printed text that is both human readable and readable by automated check processing equipment. Check processing machines use Magnetic Ink Character Recognition (MICR) to identify printed characters in a check, such as routing and account numbers, quickly and accurately. The magnetic ink includes a suspension of magnetic particles, such as iron oxide, which are detectable using a magnetic field. The use of MICR printing is widespread and enables automated processing of checks and other documents even when the printed magnetic ink characters are visually obscured by stamps or other overprinting. Automated check processing machines perform high-speed character recognition using printed magnetic ink characters to identify account and routing numbers. While check processing is one application of magnetic ink printing, magnetic inks can be incorporated in a wide range of printed documents and can be used in conjunction with non-magnetic inks as well.
One challenge in using magnetic inks with inkjet printers relates to the propensity of the magnetic inks to absorb or “bleed” into porous print media such as uncoated paper. A typical magnetic ink includes a liquid solvent holding a suspension of microscopic magnetic particles. The liquid solvent and magnetic particles are ejected in the form of drops onto the paper where the solvent evaporates, leaving the magnetic particles. During the drying process, however, the solvent and magnetic particles absorb into the fiber of the paper instead of remaining concentrated near the surface of the paper.
To reduce or eliminate bleeding, some magnetic ink printers use specially treated print media, such as wax coated papers, which reduce the porosity of the print medium to reduce or eliminate the absorption of the magnetic ink. Using coated papers, however, adds to the expense of printing documents and reduces the versatility of a magnetic ink printing system. Consequently, improvements to magnetic ink printers that improve the readability of images printed with magnetic ink would be beneficial.
In one embodiment, a method for printing magnetic ink has been developed. The method includes moving a print medium through a print zone in a process direction, ejecting a plurality of drops of a magnetic ink from a plurality of inkjets in the print zone onto a surface of the print medium, moving the print medium past a magnetic field generator located in the process direction from the plurality of inkjets in the print zone, and applying a magnetic field with an orientation that is substantially parallel to the process direction to the plurality of drops of the magnetic ink on the surface of the print medium with the magnetic field generator to increase a viscosity of the magnetic ink on the print medium in a direction that is perpendicular to the process direction extending into the print medium.
In another embodiment, a printing apparatus that is configured to print magnetic inks has been developed. The printing apparatus includes a media path configured to move a print medium through a print zone in a in a process direction, a plurality of inkjets in the print zone configured to eject a plurality of drops of a magnetic ink onto a surface of the print medium, and a magnetic field generator located in the process direction from the plurality of inkjets in print zone and configured to apply a magnetic field with an orientation that is substantially parallel to the process direction to the plurality of drops of the magnetic ink on the surface of the print medium to increase a viscosity of the magnetic ink in a direction that is perpendicular to the process direction extending into the print medium.
For a general understanding of the environment for the system and method disclosed herein as well as the details for the system and method, reference is made to the drawings. In the drawings, like reference numerals have been used throughout to designate like elements.
As used herein the term “printer” refers to any device that is configured to print images on an image receiving surface. Common examples of printers include, but are not limited to, xerographic and inkjet printers. Various printer embodiments use one or more marking agents, such as ink or toner, to form printed images in various patterns. An image receiving surface refers to any surface that receives a marking agent, such as an imaging drum, imaging belt, or various print media including paper. The term “substrate” refers to a print medium, such as paper, that holds printed images. In some embodiments, the printer is a digital printer. Digital printers enable an operator to design and modify image data to alter the image printed on the substrate easily using, for example, commercially available image editing software.
A continuous feed or “web” printer produces images on a continuous web print substrate such paper. In some configurations, continuous feed printers receive image substrate material from large, heavy rolls of paper that move through the printer continuously instead of as individually cut sheets. The paper rolls can typically be provided at a lower cost per printed page than pre-cut sheets. Each such roll provides an elongated supply of paper printing substrate in a defined width. Fan-fold or computer form web substrates may be used in some printers having feeders that engage sprocket holes in the edges of the substrate. After formation of the images on the media web, one or more cutting devices separate the web into individual sheets of various sizes. Some embodiments use continuous feed printing systems to print a large number of images in a timely and cost efficient manner.
As used herein, the term “magnetic ink” refers to an ink that includes a suspension of magnetic particles in a liquid or phase-change medium. Some magnetic inks include a suspension of particles, such as iron oxide, in an aqueous or organic based solvent. Another type of magnetic ink is a phase-change magnetic ink, such as an ultraviolet (UV) curable ink. The phase-change magnetic ink is either solid or gelatinous at room temperature and includes magnetic particles that are distributed through the phase-change ink. When heated to a predetermined melting temperature, the phase change ink melts into a liquid state with the magnetic particles suspended in the liquid ink. An inkjet printer ejects liquid drops of the phase-change magnetic ink onto an image receiving surface where the phase-change ink is exposed to a UV light source and solidifies on the surface of a print medium.
As used herein, the term “fix” as applied to an ink image refers to a process of permanently marking a print medium with an ink. When the ink includes a solvent, the fixing process includes drying the ink to evaporate the solvent and leave pigments and magnetic particles permanently in place on the print medium. When the ink is a phase-change ink, the fixing process includes spreading the liquid ink drops on the print medium and forming a durable bond between the printed ink drops and the print medium.
The media can be unwound from the source 10 as needed and propelled by a variety of motors, not shown, rotating one or more rollers. The media conditioner includes rollers 12 and a pre-heater 18. The rollers 12 control the tension of the unwinding media as the media moves along a path through the printer. In alternative embodiments, the media can be transported along the path in cut sheet form in which case the media supply and handling system can include any suitable device or structure that enables the transport of cut media sheets along an expected path through the imaging device. The pre-heater 18 brings the web to an initial predetermined temperature that is selected for desired image characteristics corresponding to the type of media being printed as well as the type, colors, and number of inks being used. The pre-heater 18 can use contact, radiant, conductive, or convective heat to bring the media to a target preheat temperature, which in one practical embodiment, is in a range of about 30° C. to about 70° C.
The media are transported through a print zone 20 that includes a series of printhead units 21A and 21B. Each printhead unit effectively extends across the width of the media and is able to place ink directly (i.e., without use of an intermediate or offset member) onto the moving media. Each of the printhead units 21A and 21B includes a plurality of printheads positioned in a staggered arrangement in the cross-process direction over the media web 14. As is generally familiar, each of the printheads can eject a single color of ink, one for each of the inks typically used in the printer 5.
Each of the printhead units in the printer 5 can use “phase-change ink,” by which is meant that the ink is substantially solid at room temperature and substantially liquid when heated to a phase change ink melting temperature for jetting onto the image receiving surface. The phase change ink melting temperature can be any temperature that is capable of melting solid phase change ink into liquid or molten form. In one embodiment, the phase change ink melting temperature is approximately 70° C. to 140° C. In alternative embodiments, the ink utilized in the imaging device can comprise UV curable gel ink. Gel ink is typically heated before being ejected by the inkjets of the printhead. As used herein, liquid ink refers to melted solid ink, heated gel ink, or other known forms of ink, such as aqueous inks, ink emulsions, ink suspensions, ink solutions, or the like.
In the configuration illustrated in
The controller 50 of the printer receives velocity data from encoders mounted proximate to rollers positioned on either side of the portion of the path opposite the printhead units 21A and 21B to compute the position of the web as the web moves past the printheads. The controller 50 uses these data to generate timing signals for actuating the inkjets in the printheads to enable the four colors to be ejected with a reliable degree of accuracy for registration of magnetic and non-magnetic ink patterns to form single or multi-color images on the media. The inkjets actuated by the firing signals correspond to image data processed by the controller 50. The image data can be transmitted to the printer, generated by a scanner (not shown) that is a component of the printer, or otherwise electronically or optically generated and delivered to the printer. In various alternative embodiments, the printer 5 includes a different number of printhead units and can print inks having a variety of different colors.
A backing member 24A and 24B is associated with each of printhead units 21A and 21B, respectively. The backing members 24A and 24B are typically in the form of a bar or roll, which is arranged substantially opposite the printhead on the back side of the media. Each backing member is used to position the media at a predetermined distance from the printhead opposite the backing member. Each backing member can be configured to emit thermal energy to heat the media to a predetermined temperature. In one practical embodiment, the backing member emits thermal energy in a range of about 40° C. to about 60° C. The backer members can be controlled individually or collectively. The pre-heater 18, the printheads, backing members 24 (if heated), as well as the surrounding air combine to maintain the media along the portion of the path opposite the print zone 20 in a predetermined temperature range of about 40° C. to 70° C.
As the partially-imaged media web 14 moves to receive inks of various colors from the printheads of the print zone 20, the printer 5 maintains the temperature of the media web 14 within a predetermined temperature range. The printheads in the printhead unit 21A eject a phase-change ink at a temperature that is typically significantly higher than the temperature of the media web 14. Consequently, the ink heats the media. Therefore, other temperature regulating devices can be employed to maintain the media temperature within a predetermined range. For example, the air temperature and air flow rate behind and in front of the media may also impact the media temperature. Accordingly, air blowers or fans can be utilized to facilitate control of the media temperature. Thus, the printer 5 maintains the temperature of the media web 14 within an appropriate range for the jetting of all inks from the printheads of the print zone 20. Temperature sensors (not shown) can be positioned along this portion of the media path to enable regulation of the media temperature. In an alternative printer embodiment, the MICR ink is a solvent-based liquid ink that dries on the surface of the media web 14 after passing the magnetic field generator 45. The solvent in the solvent-based ink dries through evaporation, and optional heaters located along the process path promote the evaporation of the solvent.
Following the print zone 20 along the media path, the media web 14 moves past a magnetic field generator 45. In one embodiment, the magnetic field generator 45 is an electromagnet that is operatively connected to the controller 50. The controller 50 selectively activates and deactivates the electromagnet 45, and also selects an intensity of the magnetic field that the electromagnet 45 generates. For example, the controller 50 activates the electromagnet 45 at the beginning of a print job that includes printing of magnetic ink, and deactivates the electromagnet 45 during maintenance operations in the printer 5 or when the printer 5 performs a print job that does not include printing with the magnetic ink. In another embodiment, the magnetic field generator 45 is a permanent magnet that is not directly operated by the controller 50. In either embodiment, the magnetic field generator produces a magnetic field having a field strength in a range of approximately 200 Gauss to 800 Gauss at the surface of the media web 14.
The magnetic field generator 45 is positioned on the same side of the media web 14 as the printhead units 21A and 21B. Thus, the magnetic field generator faces the printed side of the media web 14, and the magnetic field generator 45 aligns magnetic particles in the magnetic ink on the media web 14 in process direction P and attracts the image as a whole in direction 62. The strength of the magnetic field is insufficient to separate the magnetic particles from the ink or the image from the surface of media web 14, but the magnetic field increases the overall viscosity of the magnetic ink on the surface of the media web 14.
The magnetic field generator generates a magnetic field that is approximately parallel to the surface of the media web 14. As described in more detail below, magnetic particles in the magnetic ink drops align with the magnetic field and the viscosity of ink on the media web 14 increases due to exposure to the magnetic field. The magnetic field generator 45 is located at a sufficient distance in the process direction P from the magnetic printhead unit 21B to prevent the magnetic field from affecting magnetic ink within reservoirs and fluid channels in the printhead unit 21B or affect the flight of magnetic ink drops that are ejected by the printhead unit 21B.
During a printing operation, the magnetic ink includes properties of both a ferrofluid and a magnetorheological fluid. As is known in the art, both ferrofluids and magnetorheological fluids include a suspension of magnetic particles, such as iron particles, in a liquid medium. Ferromagnetic fluids typically have particles on the scale of several nanometers that are small enough to remain in suspension due to Brownian motion in the liquid. Magnetorheological fluids typically include larger particles with sizes on the order of one micron or above, which are usually too large to remain in suspension due to Brownian motion. In one embodiment, the magnetic particles in the ink are formed with sizes of between approximately 10 nm and 500 nm. The particles are small enough to avoid clogging inkjets in a printhead.
As part of the ferromagnetic properties of the ink, the magnetic field generator applies an attractive force to the magnetic ink, although the practical strength of the magnetic field is insufficient to pull the magnetic particles out of suspension in the ink. The magnetorheological properties of the ink enable the magnetic particles in the ink to align in chain-like arrangements along flux lines of the magnetic field from the magnetic field generator. The configuration of the magnetic particles produces an increase in the anisotropic viscosity of the magnetic ink. As used herein, the term “anisotropic viscosity” refers to a change in the viscosity that is affected by the direction of a magnetic field through the magnetic ink. For example, in the printer 5 the magnetic field from the magnetic field generator 45 generates magnetic field lines that extend in parallel to the process direction P. The anisotropic viscosity increases the viscosity of the ink in directions that are perpendicular to the magnetic field, while the ink has a lower viscosity in directions that are parallel to the magnetic field.
In
The magnetic ink includes both magnetic particles and either liquid solvent or a phase-change ink in a liquid phase. In the absence of an external magnetic field, the magnetic ink includes a substantially uniform distribution of the magnetic particles formed in a suspension in the magnetic ink. The magnetic ink behaves as a magnetorheological fluid, and the application of the magnetic field increases the viscosity of the magnetic ink in directions that are perpendicular to the magnetic field, such as in direction 340 of ink absorption and bleeding into the porous media web 14. As the viscosity of the ink in the direction 340 increases, the rate of absorption of the ink into the porous media web 14 decreases. The increased viscosity generated by the magnetic field in the magnetic ink lasts for a short period of time after the print medium 14 passes through the magnetic field, which provides sufficient time for the magnetic ink images to be fixed to the print medium. Once fixed, the magnetic particles in the ink remain substantially fixed to the print medium 14. As depicted in
Referring again to
Following the mid-heaters 30, a fixing assembly 40 is configured to apply heat and/or apply pressure to the media to fix the images to the media. The fixing assembly includes any suitable device or apparatus for fixing images to the media including heated or unheated pressure rollers, radiant heaters, heat lamps, and the like. In the embodiment of
In one practical embodiment, the roller temperature in spreader 40 is maintained at an optimum temperature that depends on the properties of the ink such as 55° C.; generally, a lower roller temperature gives less line spread while a higher temperature causes imperfections in the gloss. Roller temperatures that are too high may cause ink to offset to the roll. In one practical embodiment, the nip pressure is set in a range of about 500 to about 2000 psi/side. Lower nip pressure gives less line spread while higher pressure may reduce pressure roller life.
The spreader 40 also includes a cleaning/oiling station 48 associated with image-side roller 42. The station 48 cleans and/or applies a layer of some release agent or other material to the roller surface. The release agent material can be an amino silicone oil having viscosity of about 10-200 centipoises. Only small amounts of oil are required and the oil carried by the media is only about 1-10 mg per A4 size page. In one embodiment, the mid-heater 30 and spreader 40 can be combined into a single unit, with their respective functions occurring relative to the same portion of media simultaneously. In another embodiment the media is maintained at a high temperature as it is printed to enable spreading of the ink.
Following passage through the media path, the printed media can be wound onto a roller for removal from the system. A rewind unit 90 winds the printed media web onto a takeup roller for removal from the printer 5 and subsequent processing. Alternatively, the media can be directed to other processing stations that perform tasks such as cutting, binding, collating, and/or stapling the media or the like.
Operation and control of the various subsystems, components and functions of the printer 5 are performed with the aid of the controller 50. The controller 50 can be implemented with general or specialized programmable processors that execute programmed instructions. The instructions and data required to perform the programmed functions are stored in memory associated with the processors or controllers. The processors, their memories, and interface circuitry configure the controllers and/or print engine to perform the functions described above. These components can be provided on a printed circuit card or provided as a circuit in an application specific integrated circuit (ASIC). Each of the circuits can be implemented with a separate processor or multiple circuits can be implemented on the same processor. Alternatively, the circuits can be implemented with discrete components or circuits provided in VLSI circuits. Also, the circuits described herein can be implemented with a combination of processors, ASICs, discrete components, or VLSI circuits.
In process 200, a printer moves a print medium through a print zone (block 204). In the printer 5, the print medium is the elongated media web 14 and the printer 5 moves the media web 14 in the process direction P through the print zone 20. As the print medium moves through the print zone, the printer optionally forms ink images on the print medium with a non-magnetic ink (block 208). In the printer 5, the printhead unit 21A includes a plurality of printheads that optionally form images on the media web 14 using non-magnetic inks. While the printer 5 is configured to print non-magnetic ink prior to printing the magnetic ink, an alternative printer configuration prints magnetic ink after printing the non-magnetic ink, or prints both magnetic and non-magnetic inks substantially simultaneously.
During process 200, the printer ejects magnetic ink drops onto the print medium to form magnetic ink images (block 212). The printer 5 moves the media web 14 through the print zone 20 in the process direction P past the printhead unit 21B. The controller 50 generates a plurality of firing signal to eject drops of the magnetic ink onto the media web 14 with the inkjets in the printhead unit 21B to form magnetic ink images. In one embodiment, the printhead unit 21B includes arrays of printheads that form magnetic ink images with a resolution of 600 dots per ink (DPI) on the media web 14. The controller 50 is configured to generate the firing signals with reference to digital image data to form a wide range of characters, symbols, and graphics using the magnetic ink. Examples of magnetic ink images include numerals and symbols corresponding to routing and account numbers that are formed in checks used in the banking and financial industry. For example, the printer 5 prints numbers and symbols associated with checks using the E-13B or CMC-7 font standards. The printer 5 can also eject magnetic ink drops to form a wide range of text, graphics, and symbols on the media web 14. As described above, the printer 5 also optionally ejects drops of non-magnetic ink onto the media web 14 with the printhead unit 21A. The printer 5 can form composite ink images including both non-magnetic ink and magnetic ink.
Process 200 applies a magnetic field to the print medium and the printed magnetic ink images (block 216). In the printer 5, the print medium 14 exits the print zone 20 and continues past the magnetic field generator 45. As described above, the magnetic field generator 45 can be either a permanent magnet or an electromagnet. In either embodiment, the magnetic particles in the magnetic ink formed on the media web 14 align with the magnetic field as the media web 14 passes the magnetic field generator 45.
Process 200 continues as the magnetic ink is fixed to the print medium after application of the magnetic field (block 220). A solvent-based magnetic ink fixes to the print medium as the ink dries. During the drying process, the solvent in the magnetic ink evaporates from the media web 14. In the printer 5, the mid-heater assembly 30 applies heat to the media web 14 to accelerate the drying process before the media web 14 enters the rewind unit 90. When the magnetic ink is a phase-change ink, the printed web conditioner 80 and the spreader 40 fix the magnetic phase-change ink to the media web 14.
As described above, magnetic field generator 45 increases the anisotropic viscosity of the magnetic ink in the perpendicular direction to the magnetic field, which reduces or eliminates bleeding of the magnetic ink image into the substrate and tends to align the magnetic particles. Consequently, the magnetic particles remain near the surface of the media web 14 after the printer 5 fixes the magnetic ink to the media web 14, producing magnetic ink characters and other markings having improved readability with automated devices even when printer 5 forms the magnetic ink image on a porous print medium.
It will be appreciated that variants of the above-disclosed and other features and functions, or alternatives thereof, may be desirably combined into many other different systems, applications or methods. Various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art, which are also intended to be encompassed by the following claims.
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