Patent Application
20130127969
The present invention relates to a print head element, print head and printing apparatus including same for use in ionographic printing.
For many years printing proceeds with letterpress, gravure (intaglio) or planographic (lithographic) printing machines wherein a printing ink receptor, usually paper, makes direct contact with an inked printing form [ref. e.g. Printing Technology by J. Michael Adams et al.—Delmar Publishers Inc. (1988)].
Nowadays other printing processes, so-called non-impact printing processes have found application, e.g. electrostatic printing, and ink jet printing (ref. e.g. “Principles of Non-Impact Printing” by Jerome L. Johnson (1986)—Palatino Press—Irvine Calif., 92715 U.S.A.).
In order for these non-impact printing systems to be competitive with classical “impact” or “contact” printing they have to be adapted for high speed printing at long runs and have to possess the capability of printing on both sides (duplex printing) which is common praxis in printing of books and journals, and have to be suited for large format printing.
Two electrostatic printing systems have gained particular importance.
A first system called electrophotographic printing is based on the use of an electrostatically chargeable photoconductive member that is image wise discharged through image wise photo-exposure whereupon the residual charge pattern is developed with dry toner particles or toner particles dispersed in an insulating liquid.
A second system is based on the use of a non-photosensitive dielectric member, i.e. electrostatically chargeable member, that is charged in image configuration by various means such as electron beams, ionographic print heads, contacting electrode wires, electronic stencils or shaped masks, the development of the obtained electrostatic charge pattern being the same as described for the electrophotographic printing process.
Both said electrostatic printing processes have been described in U.S. Pat. No. 5,740,510 and 5,765,081 in connection with the structure and use of an electrostatographic multicolour printing apparatus for single pass sequential duplex printing on a web-type toner image receptor material.
While photoconductive imaging members require to be shielded against light of the environment, dielectric members used in image wise electrostatic charging have the advantage that they can hold an electrical charge in the presence of visible light which makes them more practical in commercial use and in the design of the housing of the printing machine.
At present in electrostatic ionographic printing, an electrostatic charge pattern on a dielectric member is formed by means of pattern wise ion-deposition from an ionographic print head, wherein two types of print heads may be distinguished.
A first type of ionographic print head operates with a corona wire to produce an air-assisted stream of plasma containing positive ions caused to blow out through a slit formed by a machined surface of a modulation array containing electrode fingers that can deflect said ions and locally eliminate them from the air stream. Such is realized in the commercial ionographic print head known under the “trade name” CORJET. Such device operating with corona discharge for plasma formation and ion generation is described e.g. in U.S. Pat. No. 4,743,925, and published European Patent Application EP 0578882.
A second type of ionographic print head operates with an ion generator including two electrodes, driver and control electrode, separated by a solid insulator (dielectric). When a high frequency electric field (R.F. field) is applied between said electrodes a pool of plasma containing ions and electrons is generated in an ionisable gas that has been injected into a micro chamber comprising a control electrode having a cavity facing a flat modulation electrode also called screen electrode having an aperture for output of an ion beam. Examples of such print heads producing a single type of ions are described e.g. in published European Patent Application 0 541 841 A1, U.S. Pat. Nos. 4,675,703 and 4,697,196.
In U.S. Pat. No. 4,538,163 a fluid jet assisted ion projection and printing apparatus is described wherein substantially equal numbers of positive and negative ions are generated simultaneously during a series of RF arc breakdowns which take place within an elongated fluid transport channel passing through the body of the apparatus (see e.g.
The use of a wire as RF electrode and upstanding electrode strips in the elongated channel will make it very difficult to produce such print head by planar microelectronic production techniques.
Further, it has to be stated that equal amounts of ions of opposite sign will not be produced with the ionization print head according to U.S. Pat. No. 4,538,163 when as ionisable gases noble gases such as helium and argon are used. Only plasmas containing positive ions and electrons are formed with noble gases by their chemical inactivity in accepting electrons.
The use of said noble gases in ionography operating with print head elements comprising three electrodes, viz. control, driver and modulation electrode, is described in published European Patent Application number 0 541 841 A1. As described therein it has been found that if a substantial portion of the air in the discharge region, i.e. micro chamber of the ionographic print head, is replaced with nitrogen, elemental noble gases, mixtures of noble gases, or mixtures of nitrogen with one or more noble gases, uniformity and/or print head life can be significantly enhanced. As illustrated in
An ion print head and image forming apparatus not relying on the use of driver, control and modulation electrodes as in the previous prior art is described in U.S. Pat. No. 5,406,314 (see its
Each discharge cell in said ion print head operates with a needle electrode inside a discharge tunnel (tubular channel) perpendicular in direction to the wall of said tunnel pointing toward an opposite inner wall of said tunnel. A wraparound electrode is present at an output portion of the tunnel that is adjacent to a dielectric layer serving as positive ion receiving layer for forming a latent electrostatic image thereon.
The disadvantage of said ion print head resides in the complex arrangement of a needle electrode in a small ionization tunnel perpendicular to the axis of said tunnel and the presence of said wraparound electrode inside said tunnel which does not allow the production of such discharge cells by planar microelectronic production techniques.
As is known planar microelectronic production techniques make use of coating of dielectric resin layers, photo-hardening of resin layers for forming etching-resistant portions, vapour deposition of metals, sputtering and etching of metals on slices of dielectric material in order to produce planar layered integrated circuits.
It is the object of the present invention to provide an ionographic print head containing print head elements having a non-complicated structure allowing their simultaneous production in large amounts by planar micro-electronic manufacturing techniques.
Planar micro-electronic manufacturing techniques make it possible to obtain in said print head elements very tiny ion production channels which is in favour of high image resolution. By planar micro-electronic manufacturing techniques it is possible to group said print head elements in modules that are easy mountable and replaceable in the final print head and to have the micro circuitry for addressing their ion production and modulation functions included in said modules.
According to the present invention a print head element 200 for an ionographic print head 313 is provided comprising:
Further according to the present invention an ionographic printing apparatus 292 comprises the following elements:
Further the present invention relates to a method for placing electrostatic charges by means of ions produced in an ionographic print head 313 in an image wise pattern on a dielectric substrate 214, said method including the steps of:
Specific features of particular and/or preferred embodiments are set out in the dependent claims.
An advantage of the use of a print head element according to the present invention comes from the straight flow of ionisable gas from input to output of the tubular channel in said element whereby turbulence of ionisable gas is prevented. Hereby the divergence of the jet of ions from said cells towards the receptor surface is kept very low yielding sharp ion dots necessary for obtaining high resolution non-blurred images.
A further advantage comes from the embodiment of the present invention wherein very tiny print head elements are present in redundancy in the print head grouped therein in sub-modules in staggered position. Thereby it is made practically impossible to have visible white lines produced in the final toner-developed print. Single toner particles can be held by many small ion charge dots corresponding each with very small ion production channels.
a represents a bottom view, i.e. at the ion exit side, of a row of print head elements 200 according to the present invention containing said print head elements 200 arranged in staggered position. The bottom view shows the channel apertures 207 surrounded by modulation electrodes 206 having conductive stripes 252 for their electronic addressing.
b represents a plurality of print head elements 200 arranged linearly into a group called sub module 253.
c represents a plurality of sub-modules 253 arranged on a support in staggered position to form modules 254 that allow their easy mounting and replacement in the print head 313 that has a curved surface 257 at the ion exit side.
a and 7b represent respectively a schematic side view of an ionographic printing apparatus 292 according to the present invention for printing toner images through an offset belt 319 on a flexible substrate 231, e.g. paper web or textile, and on a rigid substrate 232, e.g. wooden panel or metal plate.
From present
The driver electrode 124 is shown on a conventional backing insulator 140 which in turn is connected to an aluminium backbone 141.
The gas for ionization at the discharge region flows outwardly through the opening 132 in the screen electrode 131, along with the ions. Since a positive pressure is maintained at the discharge region it is extremely unlikely that conductive toner particles could enter that area and become sucked up into the openings of the print head, called ion cartridge.
From present
A modulation electrode 92 in the form of upright fingers in the wall of channel 46 is present on dielectric body material 94 and faces an opposing modulation plate 88. Both the modulation electrode 92 and the opposing modulation plate 88 are covered with an intermediate dielectric layer 82. Switch 96 is closed, for addressing the modulation electrode 92. A mix of positive and negative ions (see prior art
Each print head element 200 of said print head 313 has a tubular and straight channel 201 in a dielectric, i.e. electrically insulating body 202, 203, 213. At one end, i.e. at the inlet opening of said tubular channel 201, a suitable gas supplying means 216 following the print head array, e.g. a manifold having a plurality of exit openings, supplies an ionisable gas or gas mixture into said tubular channel 201. Said tubular channel 201 is surrounded by a plane driver electrode 204, and (preferably plane) control electrode 205, both said electrodes being arranged substantially diametrically to the longitudinal axis of said tubular channel 201. The driver electrode 204 is embedded in dielectric material of said dielectric body 202 and/or 203, and is separated by dielectric material from said control electrode 205. The control electrode 205 forms part of said tubular channel 201, i.e. has a border area therewith, and so can make contact with said ionisable gas or gas mixture.
A modulation electrode 206, being preferably planar, is present on dielectric body 213 and surrounds the exit opening of said tubular channel 201 forming hereby a circular aperture 207.
Between said driver electrode 204 and said control electrode 205 a high frequency voltage source 208 (RF voltage source) supplies the necessary voltage pulses for an ionisation in said channel 201 in the region between driver 204 and control electrode 205 forming therein a plasma containing ions and electrons.
In closed state (as shown in the drawing) switch 209 brings all the electrodes (204, 205 and 206) at the same direct current (DC) voltage by connecting them to the positive pole of DC source 212. The negative pole of said source 212 is grounded and through the ground connected to the backing electrode 210 of the electrostatic image receptor layer 214.
As a result of said connection the positive ions in the plasma of the tubular channel 201 are attracted and accelerated towards said backing electrode 210 and deposited on the electrically insulating layer 214.
In open state switch 209 raises by means of DC voltage source 211 the voltage of modulation electrode 206 to a higher level than present at the electrodes 204 and 205. As a result thereof the positive ions of the plasma are blocked from reaching the electrically insulating layer 214. Both the control electrode 205 and modulation electrode 206 being connected to the positive pole of direct current (DC) source 211 serve as a drain for the electrons of the plasma.
According to a particular embodiment the RF voltage applied to the driver electrode 204 is 200 to 500 volt peak to peak. The frequency of the cyclic voltage change of source 208 is 100 kilohertz (kHz) to 10 Megahertz (MHz). The DC voltage of source 211 when operating with tiny tubular channels 201 can be kept fairly low, viz. between 3 to 10 volt, whereas the DC voltage of source 212 is then in the range of 200 to 500 volt.
The dielectric body 202, 203 and 213 of the print head element 200 according to the present invention can have a single material structure or is composed of a number of different layers of same or different material type with the proviso that they are all dielectric materials, e.g. silicon dioxide, aluminium oxide and silicon nitride. When uniting different inorganic layers of dielectric materials as defined above (photo) hardenable silicones may be used. The thickness of the electrodes does not have to be the same for all electrodes. The control electrode may be the thickest.
Typical suitable materials for forming the electrodes (205, 206) are metals resistive to corrosion, e.g. molybdenum, tantalum and tungsten. The driver electrode 204 being shielded from the plasma by the dielectric body material can be made of silver, copper or aluminium.
According to a preferred embodiment for ionographically printing with a print head 313 according to the present invention the aperture 207 of the modulation electrode 206 is circular and has a diameter in the range of 0.4 to 40 micrometer, more preferably 0.4 to 10 micrometer.
The ratio of aperture diameter to tubular channel length is preferably in the range of 2/1 to 1/5.
The diameter of the tubular channels 201 is not necessarily constant over their whole length with the proviso however, that the above defined aperture diameter is present. By the applied hole-etching process in the formation of said channels a funnel-like structure may be obtained therein, but the largest tubular channel diameter is preferably not more than 60 micrometer.
According to a preferred embodiment the present printing head elements 200 are used in conjunction with dry toner particles having an average weight toner size of at least 5 micrometer, more preferably in the range of 5 to 10 micrometer. The ratio of the average weight toner particle size to the diameter size of the exit aperture 207 of the tubular channel 201 is preferably in the range of 10/1 to 30/1.
According to a particular embodiment in the development of the electrostatic charge images obtained by ionographic printing electrically conductive dry toner particles are used in combination with the present ionographic print elements, such for the advantage that these particles in occasional contact with a charged electrically conductive body such as the modulation electrode are repelled by the law of induction. Said law requires that once an electrically conductive particle has taken the charge of a charged conductive body, e.g. an electrode, it obtains the charge sign thereof and becomes repelled thereby. So, a voltage modulated apertured electrode will not be covered or blocked by electrically conductive toner particles.
According to a particular embodiment conductive toner particles having a conductive substance in the bulk are used, the bulk conductivity of which is at least 1011 Siemens per centimeter, an example of which can be found in U.S. Pat. No. 06467871.
According to a special embodiment conductive dry toner particles are used that have shell-core structure in which the shell composition provides an inductive charge separation in the neighbourhood of an electrostatically isolated charge pattern, i.e. here an ion charge pattern, to become attracted thereto.
Useful for the purpose of development of ionographic charge images are core-shell toner particles having a conductive shell as described in published European Patent Application 0 441 426 A1. Said toner particles carry on their surface and/or in an edge zone close to the surface fine particles of electrically conductive material consisting of fluorine-doped tin oxide. The fluorine-doped tin oxide particles have a primary particle size less than 0.2 micrometer and a specific electrical resistance of at most 50 Ohm.meter. The core of said particles is made e.g. of thermoplastic polyester and may contain magnetically attractable pigment.
In order to obtain stable and high ionization results the present print head elements are not operated with air but preferably with a noble gas or mixture thereof with nitrogen. Particularly preferred is the use of pure helium or a mixture of helium and argon gas by means of which a plasma containing positive ions and electrons is produced in an alternating field of sufficient strength.
When the major part of the ionisable gas is helium intensely charged ion beams can be formed which is particularly advantageous when operating with very tiny ionization channels. Such has to do with the fact that helium ions apart from hydrogen ions have the highest electrostatic charge to mass ratio. Argon is preferably present to some amount because argon has a fairly low ionization energy of 15.8 eV and thus operates as an ionization starter, whereas helium requires 24.6 eV being higher than that of nitrogen (14.5 eV). The restricted presence of argon is for the fact that argon in ionized state has sputtering properties which will affect the materials, e.g. thin electrodes in contact therewith.
It is general knowledge that physical sputtering is driven by momentum exchange between the ions and atoms in the surrounding material. Argon forming already relatively heavy ions is therefore detrimental to the structure of thin-film deposited active parts of an ionographic print head.
The helium-argon gas mixture applied according to the present invention contains preferably argon in no more than 20 volume percent with respect to helium. More preferably argon is present in admixture with helium in an amount between 0.5 and 10% by volume. Particularly suited is said gas mixture for use in high image resolution ionographic printing applying micro channel print head elements having very thin tubular ionization channels, whereby very fine ion beam spots at relatively low voltage gradients are produced.
According to a preferred embodiment for fully preventing blocking of electrode apertures, e.g. with errant toner particles, the mixture of helium and argon is supplied at more than atmospheric pressure.
b represents a plurality of print head elements 200 arranged linearly in a group called sub module 253, the encircled part corresponds with the enlarged part of 251 of
c represents a perspective view of an arrangement in a module 254 of sub-modules 253 placed in staggered position. Each module 254 forms an easily mountable and replaceable part of the print head 313 having a curved surface 257 at the ion exit side.
A print head 313 according to the present invention makes part of said electrostatic imaging station 222 and faces an electrically insulating layer 214 applied on an electrically conductive cylindric support 210 of drum 320. The print head 313 projecting an ion image onto said electrically insulating layer 214 is followed in order by a toner development station 314, a cleaning station 315 for removal of superfluous toner particles i.e. for picking up e.g. by suction, non image-wise deposited toner particles, and a toner image transfer zone 328. In said zone 328 the toner image is transferred onto the supported resilient layer 319 of the rotatable intermediate toner-image receiving drum 317.
The toner image transfer zone 328 is followed by a cleaning station 310 in the form of a brush associated with a cleaning blade 322 and suction device 323 for removing toner particles left after toner image transfer. In succession therewith follows a station 326 for applying a powder material like polytetrafluorethylene having a contact angle with respect to water of at least 87° (ref. The Polymeric Encyclopedia volume 5, ed. in chief Joseph C. Salamone, CRC Press, 1996, ISBN 084932470X, p. 3192) or polyethylene having a contact angle with respect to water of at least 70° (ref. Surface characteristics of fibers and textiles, ed. Christopher M. Pastore and Paul Kiekens, CRC Press, 2000, ISBN 0824700023, p41).
Said station 326 contains a tube like vessel 325 in which a rotating helix pushes finely divided polytetrafluorethylene powder having an average grain size of 0.2 micron onto a soft brush 311, wherefrom it is sprinkled onto the electrically insulating layer 214 of drum 320. A rotating soft brush 329 smoothens the applied powder layer optionally filling up micro pores in the electrically insulating layer 214 that may be made of anodized aluminium.
According to a preferred embodiment the toner development station 314 is a fluidized bed development apparatus, e.g. of the type described in U.S. Pat. 3,380,437.
Members 236 represent intermediate fixing stations. The final fixing of the toner images on the paper web 231 proceeds in station 293. The members 294 represent guiding rollers. After passing a cutting station 223 printed paper sheets 224 arrive finally in a receptor tray 225.
a and 7b represent respectively a schematic side view of an ionographic printing apparatus according to the present invention capable of printing respectively toner images onto a flexible substrate 231, e.g. paper web and onto a rigid substrate 232, e.g. wooden panel or metal plate.
An offset belt 319 serving as receiving member for different toner images is rotatably driven by a rotatable guiding member 318 being a drum operating together with roller(s) 334 and contacts rotatably driven imaging stations 222 containing different coloured toners for multicolour printing.
Printing paper 231 in web form is fed from a paper supply roller 227 and is passed in the nip formed by said offset belt 319 and a backing roller 229. Said backing roller 229 is a hot fuser roller kept under pressure towards said toner-receiving offset belt 319. The belt 319 is preheated in station 226 and cooled after toner-image transfer in station 237 preceded by a cleaning station 230. The pressure applied in the nip of said backing roller 229 and the offset web 319 makes that the paper is moved in synchronism with the peripheral movement of the guiding drum 318, which is coupled to a speed controllable electric motor (not shown in the drawing).
Member 235 is a preheating station for raising the temperature of the substrate 231 or 232 to be printed improving the fixing.
Following the toner image transfer the offset belt 319 passes a cleaning station 230. The paper web 231 carrying fixed toner images is cut in a cutting station 223 whereupon printed sheets 224 are received in a tray 225.
b shows how a rigid panel 232, e.g. a wooden panel, receives a multicolour print. The panel 232 is conveyed on a roller bed 233 into the nip formed between the already mentioned offset belt 319 and the pressure roller 229. All the other elements shown in the drawing are the same as in
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/IB10/53533 | 8/4/2010 | WO | 00 | 2/4/2013 |
