Compression set and compression stress relaxation are both physical properties of materials. These properties are discussed or disclosed for specific materials in elastomeric material data sheets. A measurement of compression set is the percent reduction in dimensional thickness of a material after the material is compressed for a fixed time and at a fixed temperature. A measurement of compression stress relaxation is the reduction in restoration force of a material as the material is being compressed at a constant strain for a fixed time and at a fixed temperature.
Compression set and compression stress relaxation cause negative side effects in platen rollers. For example, a platen roller used in a thermal printer that prints two different media widths experiences negative side effects due to compression set and compression stress relaxation. Specifically, if too many sheets of the smaller width media are printed, especially during an initial utilization, (the initial utilization being approximately the first 1000 prints or the first five percent of the printer life), the rubber in the center portion of the platen roller experiences compression stress relaxation. The rubber in the center portion of the platen roller refers to or corresponds to the location on the platen roller corresponding to the width of the small width media. As a result of the compression stress relaxation, when the larger width media is printed utilizing the platen roller, an image artifact of lighter optical density appears on the larger width media in the location that corresponds to the width of the small width media.
Optical density may be represented in a range from 0 (open air) to 4 (very black). The measurement of optical density is a logarithmic scale where the optical density (OD) value is a negative exponent of the log base 10 value of light transmission (T=10−OD). Light transmission is usually expressed in terms of a percentage, e.g., if OD=0, the light transmission is equal to 100% and all light is being transmitted: if OD=1, light transmission is 10%; if OD=2, light transmission is 1%; if OD=3, light transmission is 0.1%, and if OD=4, light transmission is 0.01%. If one part of a film has a different “background OD” than another part of the film, then the part of the film with the different background OD is considered to have an image quality artifact.
As noted above, this image quality artifact is a degradation of the image quality for the film because the used portion of the roller produces the different optical density on the film when compared to the unused portion. This lighter density is attributed to the reduction in reaction force by the relaxed rubber (in the center portion of the platen roller corresponding to the width of the small width media) which results in less thermal pressure/contact at the media and printbead nip. DIN 6868-56 is a regulatory standard for medical hard copy film imagers and requires that the images produce prints to meet certain image quality guidelines. If the film has a certain number or a certain percentage of image artifacts, the hard copy film imager generating the film may not meet regulatory standard DIN 6868-56, and this makes the medical image printer unusable in a medical imaging environment.
In addition, compression set and compression stress relaxation also cause negative side effects in gasket and O-ring materials. Gasket and O-ring materials tend to leak over time and can no longer provide a sufficient seal. In some cases, this is a result of the gasket or O-ring material relaxing. Initially, when a gasket is tightened, the force that the gasket exerts (pushes) against the mating parts is sufficient to seal properly. This force reduces over time as a result of the compression set and compression stress relaxation property of the gasket and O-ring materials, thus causing the leak.
A prior method to reduce the negative effects of the compression set and the compression stress relaxation is to select a different material for the platen roller, the O-ring, or the gasket. At the molecular level, compression set and compression stress relaxation are the result of the breaking (and subsequent reforming while compressed to try to achieve the lowest energy state) of cross-links in the molecular chains of the compound or material which is utilized to make the roller, O-ring, or gaskets. In order to reduce the breaking of these cross-links, a solution is to utilize a material that is a higher durometer material, i.e., a harder material. In other words, the durometer must be increased. This is a challenge in many applications because, for example, in an application utilizing platen rollers, this would cause small defects in the roller surface to be more likely to show up on the image (if it is a high durometer vs. a low one). In the case of an O-ring, temperature and pressure cycling causes movement of the seal and a high durometer O-ring may not be flexible enough to accommodate this variation and still provide an adequate seal. In other words, a lower durometer material may provide other benefits and these benefits may be essential or beneficial to the functioning of the apparatus that utilizes the roller, O-ring, or gasket. Also, selecting a different material (compound) may result in chemical compatibility issues with other materials being utilized in the apparatus.
Accordingly, a need exists to have rollers made of a lower durometer material which is not as influenced by compression set and compression stress relaxation in a printing environment where a large format media width and a small format media width are utilized. A need also exists for O-rings, and gaskets to maintain sealing properties and to not leak due to the onset of compression set and compression stress relaxation.
a) illustrates restorative force of two materials according to the prior art;
b) is a graph illustrating a compression stress relaxation curve after pre-aging rollers according to an embodiment of the invention;
a) illustrates a change in optical density for a standard roller compared to a pre-aged roller (exposed to a hydrostatic chamber) according to an embodiment of the present invention;
b) illustrates application of a pressure over a duration of 12, 24, and 48 hours in a hydrostatic pressure chamber pressurized at 90 pounds per square inch;
a) and 3(b) illustrate an embodiment of the invention for dynamic loading of a platen roller according to embodiments of the present invention;
c) illustrates a fixture for applying pressure according to an embodiment of the present invention;
d) illustrates an exploded view of the fixture for applying pressure according to an embodiment of the present invention;
e) illustrates a change in optical density in a roller that is placed in the pre-aging process fixture according to an embodiment of the invention;
a) and 4(b) illustrate a pre-aging technique for flat or a complex-shaped structure or geometry according to an embodiment of the invention;
c) illustrates a plurality of pressure apparatus and a complex geometry O-ring or gasket according to an embodiment of the present invention; and
b) is a graph illustrating a compression stress relaxation curve after pre-aging rollers according to an embodiment of the invention. Material 2 is a lower durometer material which is more desirable to be utilized in an imaging printing environment. As shown in
b) illustrates the effect of the pre-aging technique or method on rollers made of material I and material 2. The pre-aging process is completed for a pre-aging timeframe or process. In comparing the restorative force for material 2 during the pre-aging process against the prior art (
In an embodiment of the invention, the plurality of forces 212, 214, 216, 218, 220, 222, 224, 226, 228, 230, 232, and 234 illustrated in
In an embodiment of the invention, the hydrostatic pressure is applied by surrounding the roller with a pressurized gas in a pressurized chamber. In an embodiment of the invention, the hydrostatic pressure may be applied by a pressurized liquid in a pressurized chamber. The pressurized chamber may be any shape having a volume that allows for one or for a plurality of platen rollers to be placed in the pressurized chamber. The pressurized chamber may include a shelf or a ledge where the platen rollers, O-rings, or gaskets may be placed when undergoing the application of hydrostatic pressure. For example, the pressurized chamber may be a two foot by three foot rectangular chamber with an inlet or input port having a diameter of ¼″. In an embodiment of the invention, the pressurized chamber may be a 2′ by 3′ cylindrical tank that receives a specified atmospheric pressure through a ¼″ port.
In an embodiment of the invention, the pressurized gas may be compressed air. In an embodiment of the invention, the pressurized gas may be compressed nitrogen. In certain environments, compressed nitrogen may be easier to use on a production basis because compressed nitrogen is more inert than air. Additional illustrative gases, (this list is not meant to be limiting), may include noble gases which are very inert at room temperature. These gases include helium, neon, argon, krypton, and xenon. Certain gases may not be used if they cause a chemical reaction with the particular material being utilized for either the platen roller, O-ring, or gasket. For example, fluorine gas likely produces a reaction with the silicone rubber platen roller of a Codonics Horizon™ Multi-Media Imager and should not be utilized in a pressurized chamber where pre-aging of platen rollers is performed.
In an embodiment of the invention, the liquid may be water introduced into the chamber via the input port. In an embodiment of the invention, the liquid may be vegetable oils, glycerol, and/or isopropyl alcohol. These examples are merely illustrative and are not meant to be limiting. Liquids may be utilized in environments where pressure may need to be relieved safely because gases may “explode” if they for some reason rapidly expand, for example, if there is a processing equipment malfunction.
In an embodiment of the invention, the applied pressure within the compression chamber may be 90 pounds per square inch. In an embodiment of the invention, the applied pressure within the compression chamber may be 200 pounds per square inch. Almost any range of pressures 0-500 pounds per square inch (psi) may be utilized if platen rollers are placed in the compression chamber. As the applied pressure is lowered, the effect of the pressure may take longer. In other words, at a pressure of 20 psi, it may take three or four times the duration to introduce the same compression set or compression stress relaxation as compared to an applied pressure of 90 psi. The upper range limited only by where the deflection in the material cause by the hydrostatic loading exceeds the elongation limits of the material being utilized in the platen roller, O-ring, or gasket. If the deflection in the material exceeds the elongation limits of the material being utilized in the platen roller, O-ring, or gasket, damage would be visible on the surface of the platen roller, O-ring, or gasket. For example, in an embodiment of the invention utilizing gaskets or O-rings, up to 2000 psi may be utilized, if 2000 psi does not result in deflection in the material exceeding the elongation limits of the material.
a) illustrates a change in optical density for a standard roller compared to a pre-aged roller (exposed to a hydrostatic chamber) according to an embodiment of the present invention. Larger changes in optical density are not desired in imaging printers because these larger changes result in artifacts within the medical images.
In an embodiment of the invention, the duration that the pressure may be applied is 12 hours. In other embodiments of the invention, the pressure may be applied for 24, 36, or 48 hours.
In an embodiment of the invention, the pressure may be applied at 90 psi for 12 hours, which results in a material of which the platen roller, O-ring, or gasket is constructed exhibiting the desired compression set and compression stress relaxation properties which do not change substantially over time. In an embodiment of the invention, the pressure may be applied at 200 psi for 5 hours which also results in a material exhibiting the desired stable compression set and compression stress relaxation properties. In an embodiment of the invention wherein a platen roller is exposed to 90 psi pressure for 12 hours and also longer durations, the compression set and compression stress relaxation within the first 12 hours does not change drastically if the pressure is applied for a longer period. In other words, the pre-aging may occur and most of the deflection or change of roller, gasket, and O-ring material may occur during this timeframe. After that, the curves tend to flatten out (as is illustrated in
In an embodiment of the invention, the hydrostatic pressure may be applied at a constant pressure which results in a static loading. In an embodiment of the invention, hydrostatic pressure may be applied at a variable pressure which may result in a dynamic loading. In an embodiment of the invention, the hydrostatic pressure may be applied for a first timeframe, no pressure (or a lessened pressure) may be applied for a second timeframe, and this may continue for a pre-established timeframe. This may be referred to as cycling of hydrostatic pressure. This cycling of high hydrostatic pressure and no or low hydrostatic pressure may be continued for the entire pre-aging timeframe. In an embodiment of the present invention, the cycling may occur with multiple pressure readings or pressurizations rather than a high pressure and no pressure.
The aspect ratio of the roller 210 may also have an impact on whether the pre-aging process is successful for platen rollers, O-rings, or gaskets. The aspect ratio may utilize the length, width, thickness, and height of a roller 210 and may impact on the efficiency of the roller 210. If the length, width, and height of the material which makes up the roller or the roller jacket 205 is not compressible, the material may not deflect. For example, if the roller jacket is a rubber sphere, which has an aspect ratio of 1 (i.e., the cross section is the same in all planes, then the sphere will not deflect because the rubber is incompressible. Accordingly, no pre-aging occurs with a rubber sphere roller jacket. A thin jacket roller 205 having a better ratio of diameter to the jacket thickness is deflectable, which allows for better radial compression while under hydrostatic pressure. Because the thin jacket roller 205 is deflectable, the pre-aging method utilizing hydrostatic pressure may improve the imaging characteristics of the roller 210. Accordingly, the larger the cross section of the jacket is relative to the circumferential area of the material being subjected to the pressure, the less effective the pre-aging process is. In an embodiment of the invention, the roller jacket thickness is 0.062″ thick on a 0.75″ diameter roller, where the roller is 14.5″ in length. In this embodiment of the invention, the aspect ratio (i.e., the circumferential area divided by the cross sectional area) is 81 and pre-aging is effective.
a) and 3(b) illustrate an embodiment of the invention for dynamic loading of a platen roller according to embodiments of the present invention. In this embodiment of the invention, the platen roller is not stationary and mechanical forces press against the platen roller 310. The mechanical forces may be applied via multiple roller sets. Although
a) illustrates a platen roller 310 and three pressuring rollers 320, 330 and 340.
In an embodiment of the invention, illustrated in
In embodiments of the invention where the platen roller 310 is not rotating, one or more of the pressuring rollers may be rotating at a time. In other words, in these embodiments of the invention, one pressuring roller may be rotating for two seconds, a second pressuring roller may be rotating for a second set time, a third pressuring roller may be rotating for a third set time, and a fourth pressuring roller may be rotating for a fourth set time. Likewise, pairs of pressuring rollers or triples of pressuring rollers may be rotating at the same time while the other rollers of the roller set are not rotating.
In the embodiment of the invention illustrated in
c) illustrates a fixture for applying pressure according to an embodiment of the present invention.
In the embodiment of the invention, the bottom right vertical support plate 392 and the bottom left vertical support plate 396 are connected to the bottom plate 391. The top right vertical support plate 393 and the top left vertical support plate 397 are connected to the top plate 395. A pressuring roller 320 is connected, in one embodiment, via bearings 398 to the top right vertical support plate 393 and the top left vertical support plate 397. The pressuring rollers 340 and 330 are connected to the bottom right vertical support plate 392 and the bottom left vertical support plate 396 via bearings 398. The platen roller 310 fits into an opening 394 in the bottom right vertical support plate 392 and the bottom left vertical support plate 396. One end of the platen roller 310 includes a bearing 398, a gear 390, and a washer 399. The other end of the platen roller 310 includes a bearing 398, and a washer 399.
In the embodiment of the invention illustrated in
In the embodiment of the invention illustrated in
In an embodiment of the invention, the deadweight load may be 10, 15, 25, 30, or 40pounds. The mass of the deadweight load is determined by knowing the pressure to be applied to the roller in order to initiate the pre-aging process and start the compression set/compression stress relaxation process. For example, the application of 25 pounds on a platen roller equates to 3.1 pounds per linear inch of the platen roller length. In an embodiment of the invention, the deadweight load may be applied for one day, one week, two weeks, eighteen days, or one month. The duration of the application of the deadweight load is determined based on the characteristics of the material of the platen roller 310 and how much weight is applied (i.e., the deadweight load).
e) illustrates a change in optical density in a roller that is placed in the pre-aging process fixture according to an embodiment of the invention. The higher line represents the change in optical density for a platen roller of the prior art. The lower line represents the change in optical density after a set number of prints for a platen roller exposed to the pre-aging process in the three-roller set utilizing a fixture. As is illustrated in
a) and 4(b) illustrate a pre-aging technique for flat or a complex-shaped structure or geometry according to an embodiment of the invention. In embodiments of the invention, the flat or complex-shaped structure or geometry may be an O-ring or a gasket. The O-ring or gasket may be formed of a low durometer material. The low durometer material may be, for example, Neoprene, Silicone, Urethane, EPDM, or Buna-N.
In the embodiment of the invention illustrated in
In the embodiment of the invention illustrated in
c) illustrates a plurality of pressure apparatus and a complex geometry O-ring or gasket according to an embodiment of the present invention.
In an embodiment of the invention, for each iteration of the pre-aging cycle, i.e., steps 530 and 540—printing of small format media sheets and large format media sheets, a different number of media sheets may be printed out. Illustratively, under certain operating conditions, during the first iteration, ten small format media sheets may be printed and 30 large format media sheets may be printed while in the second iteration, twenty small format media sheets may be printed and 40 large format media sheets may be printed. In an embodiment of the invention, during each iteration of the pre-aging method, the same number of small format media sheets and a different number of large format media sheets may be printed (with the different number of large format media-sheets being the same for each iteration). For example, for each iteration of the pre-aging method, 2 small format media sheets may be printed and 10 large format media sheets may be printed.
In an embodiment of the invention, the roller pre-aging software program may keep the ratio of small format media sheets to large format media sheets the same during each iteration so the roller pre-aging software program may print out a corresponding (in terms of ratio) small format media sheets to large format media sheets. For example, in iteration one of the roller pre-aging software program, two small format media sheets may be printed and six large format media sheets may be printed. In the second iteration of the roller pre-aging software program five small format media sheets may be printed and fifteen large format media sheets may then be printed. In this example, the ratio remains three large format media sheets to one small format media sheet.
In an embodiment of the invention, the media may be film for printing images. Alternatively, the media may be small format and large format bond paper. The ratio of small format to large format is established to minimize the negative effects of the compression set and compression stress relaxation of the roller. The result of the this pre-aging software program is that there is a minimal differential in material relaxation and set between the portions of the roller that are compressed with just the large format media (edges of roller) and the portions of the roller that are compressed by both the large and small format media (center of the roller).
Illustratively, the roller pre-aging software program may print an image on one small format media sheet followed by 2 large format media sheets, followed by two small format media sheet followed by four large format media sheets. The software program continues this printing until either a time threshold is reached, e.g., 8 hours or 16 hours, or a print threshold is reached, e.g., 5,000, 10,000, or 20,000 prints). After either the time threshold or print threshold is reached the relaxation and the compression set of the media is relatively stable and minimal changes may occur.
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