An important part in a large format printer is the print platen. The print platen provides a very controlled flat surface to support print media that is to be printed on. In inkjet printing systems, maintaining a defined distance between the media and the ink pen, also referred to as printhead-to-paper spacing (PPS), it is important to achieve good printing quality and avoid any media crash while printing. One approach of maintaining media in place is by applying a hold down force normal to the print platen surface via a vacuum system.
For feeding the media across the print platen and the print zone, it is possible to use feed rollers downstream and/or upstream of the print zone provided by the print platen. It is also possible to use a vacuum belt running across the print platen and transferring the vacuum to the print media via a number of vacuum holes provided in the belt.
Examples of this disclosure are described below with reference to the drawings, wherein:
The present disclosure describes a print media support assembly including a print platen structure operating with a vacuum system and using a vacuum belt. The print platen structure comprises a single part or multiple-part print platen having a number of through holes for applying a vacuum to the surface of the print platen structure, and a number of sinkholes in the surface of the print platen structure. Each sinkhole is associated with at least one through hole for distributing a vacuum, applied via the through holes, across the surface of the print platen structure. The vacuum can be applied via a vacuum chamber provided at the bottom side of the print platen structure, wherein the vacuum is supplied to the vacuum chamber by a vacuum generator, such as a fan. One vacuum chamber for the entire print platen or several vacuum chambers for sections of the print platen may be provided.
The print platen structure supports a print medium in a print zone and the vacuum is holding down the media, providing the flatness needed for an accurate ink dot placement.
The print media support assembly of this disclosure also includes at least one vacuum belt running across the surface of the print platen structure in a direction of the print media advance in order to transport the print media through the print zone. The vacuum provided via the through holes and the sinkholes generates a sufficient force normal to the media to hold the media against the belt and to avoid any risk of slippage of the media relative to the belt when the print media is transported by the vacuum belts.
The one or more vacuum belts are overlapping with only part of the surface of the print platen structure to form at least one belt area, covered by the belt, and at least one non-belt area or exposed area of the print platen structure. In one example, media transport is achieved using a system of several belts, such as two, three, four, five, or six belts, without being limited to any particular number of belts. These belts, whose total width is less than the total print platen width, are running across the print platen surface and use the vacuum to hold and to keep flat or “iron” the print media. The vacuum effect is based on vacuum holes provided in the belts which are fed by the sinkholes and through holes provided in the print platen structure.
In the print media support assembly of this disclosure, at least one of the size and the density of the through holes and the distribution, the area and the shape of a footprint of the sinkholes in the print platen structure is different between the belt area(s) and the non-belt area(s). Adjusting the density and/or the size of the through holes and the distribution, the size and/or the shape of the sinkholes between the belt area(s) and the non-belt area(s) allows to properly feed the vacuum holes in the belt and to minimize friction between the belt and the print platen surface. Holding down the media on the belt using vacuum introduces friction to the belt drive because of the friction between the belt and the platen surface with the normal force of the vacuum. By properly adjusting the distribution and size of the through holes within the platen in combination with the distribution, size and shape of the sinkholes, the holding and “ironing” effect of the vacuum can be optimized while minimizing friction. This allows to control media flatness and to avoid loss in vacuum in the different areas across the surface of the print platen structure.
In one example of this disclosure, the print platen structure provides a print platen of a large format printer, and provides a print zone, a print media input zone and a print media output zone, as described in further detail below. In one non-limiting example, the print platen measures 1050 mm×350 mm wherein the print zone area only measures about 1050 mm×20 mm and hence only represents about 6% of the total area of the print platen. Constructing a print platen of this or a similar size, e.g. from a plastic part of about 1000 mm×350 mm, having a required flatness of e.g. 0.1 mm, necessitates complex production technology and is costly. The present disclosure hence proposes to separate any larger print platen structure into a number of print platen modules; in the present example, the three print platen modules 12, 14, 16 are provided which, in this example, each have a size of 333 mm×350 mm. These numbers only serve as examples and do not limit the present disclosure to any particular size of the print platen structure or number of print platen modules.
The modular design of the print platen structure, which in this example is split in three print platen modules 12, 14, 16, each having an associated vacuum chamber and vacuum generator (such as a fan), helps to reduce loss in pressure when different media sizes are used. When, for example, a print medium is used, the width of which is equal to or smaller than the width of two of the print platen modules, the vacuum generator of one of the modules can be deactivated.
At the interface of two adjacent print platen modules 12, 14 and 14, 16, measures are taken to provide good vacuum performance and to avoid loss of vacuum, as described in detail further below. In one example of this disclosure, the adjacent print platen modules overlap each other at said interfaces and a closed cell foam member is sandwiched between the overlapping side edges of adjacent print platen modules in order to obtain a good seal between the print platens. Hence vertical air flow from gaps between print platen modules at the top surface of the print platen structure can be avoided.
This type of media advance system may introduce friction due to the normal force which the vacuum applies to the belt 30. The friction force F is the product of the normal force N and the friction coefficient μ: F=N'μ
The normal force N, in turn, is the product of the pressure P and the hydraulic area A: N=P×A
In this case, the hydraulic area A is the area of the footprint of the sinkhole which feeds the vacuum hole 32 of the belt. It is desirable to keep the friction as low as possible. In theory, there would be three parameters for reducing the friction force:
If the friction coefficient of the print platen surface or the belt surface could be reduced, a lower friction force would be generated. However, in most print media support systems, the material of the print platen and the vacuum belt are defined in terms of material compatibility and other factors and hence should not be changed. Another way of reducing the friction would be to reduce the pressure generated by the vacuum chamber. However, the pressure value is chosen in order to securely hold, transport and keep flat all possible supported print medias so that this value cannot be changed arbitrarily. The third option for reducing the friction force is to reduce the hydraulic area which is defined by the area of the sinkholes, e.g. by their length and width. In order to provide a continuous vacuum to the vacuum belt and hence to the print media transported, the sinkholes should be arranged adjacent to each other, with little spacing, in the direction of media transport so that there is no gap in the vacuum supply. The length of the sinkholes 38 basically is defined by the total length of the print platen and the number of sinkholes allowed for assuring good vacuum performance when the vacuum holes are uncovered. On the other hand, the width of the sinkholes 38 is a variable parameter and, for reducing the area of the sinkholes, the width could be reduced down to the diameter of the through hole 32, +/− a worst case of belt displacement in the transverse direction (perpendicular to the media advance direction), so as to still ensure that all of the vacuum holes within the belt 30 are fed by the sinkholes. Given these parameters, examples of the present disclosure provide an optimum combination of the density and the size of the through holes 36, and the distribution, the area and shape of the footprint of the sinkholes 38 to ensure an optimum media hold down force and a minimum frictional force between the print platen structure and the vacuum belt. This can be achieved by varying at least one of the density and the size of the through holes and the distribution, the area and the shape of the footprint of the sinkholes differently between the belt areas and non-belt areas.
In the transverse direction, the print platen module 12 further may be divided into a print zone 54, a media input zone 56 and a media output zone 58. During operation of the printer, a print medium hence will be transported in the longitudinal direction, in the drawing from top to bottom, entering through the media input zone 56, then reaching the print zone 54 and leaving via the media output zone 58.
As shown in
In the belt area 50, the combination of the print platen structure and the belts introduces a relatively high friction due to the normal force on the belt caused by the vacuum. In this region, it is desirable to minimize the hydraulic area of the sinkholes ensuring a good vacuum performance. In one example, the width of the sinkholes is made as small as the diameter of the through holes +/− the worst case of belt displacement in the transverse direction in order to ensure the feeding of the belt holes under all operating conditions. The width of the sinkholes in the belt areas can be e.g. about 4 mm, in each of the print zone, the media input zone and the media output zone.
To define the sinkhole length, in the longitudinal direction, it is differentiated between the print zone 54, the media input zone 56 and the media output zone 58. The sinkholes are working best when they are fully covered. In order to obtain a good vacuum in the print zone 54, the length of the sinkholes in this area corresponds to about half of the length of the print zone, e.g. about 10 mm. For the rest of the print platen module, having a high vacuum is less critical, because the requirement of media flatness is less critical. The length of the sinkholes in the media input zone 56 and the media output zone 58 hence is considerably larger than in the print zone and may be in order of about 35 mm for the media input zone and about 30 mm for the media output zone. In the example described, the sinkholes in the belt area have the shape of an elongated rectangle, having rounded corners, with a minimum width as explained above and of varying length depending on the area where the sinkholes are located. The sinkhole length is shortest in the print zone 54 and longest in the media input area 56. As also shown in
In the non-belt area 52, which is not an interplaten area, the sinkhole shape of this example has been chosen to be a rhombus. A sinkhole having the footprint of a rhombus is advantageous in that the vacuum progressively increases and decreases and hence peaks of friction during media advance are avoided. The strategy of distributing the relative sizes of sinkholes in the non-belt area, between the print zone 54, the media input zone 56, and the media output zone 58, is similar to the belt area strategy. In one example, the width for all of the sinkholes is the same and may be about 8 mm, in one example it is 7.7 mm. The length of the sinkholes (in the longitudinal direction) in the print zone is the shortest, such as 10 mm and the length of the sinkholes in the media input zone and in the media output zone is considerably larger, for example 32 mm for the media input zone and 27 mm for the media output zone.
More generally speaking, in both the belt area and the non-belt area, the footprint of the sinkholes has a first size in the print zone, a second size in the media input zone, and a third size in the media output zone; wherein the first size is smaller than the second size and the third size, and the third size is smaller than the second size. In one example, the width of the sinkhole is the same among the sinkholes in the belt area and it is the same among the sinkholes in the non-belt area but the length of the sinkholes varies between the print zone, the media input zone and the media output zone. The above numbers and shapes are only examples and serve to illustrate the relative dimensions which will vary according to the size of the print platen structure including the different zones, the printing technology, the materials used, the nature of the print medium to be printed on and similar factors.
In the examples of a print platen structure which is relatively large, having a print media input zone and a print media output zone which are considerably larger than the print zone, the following relative dimensions may be encountered: the print zone length is about 5% to 10% of the total length of the print platen, e.g. 6%, 7%, 8%, or 9% of the total length of the print platen. The length of the media input zone is about 30% to 50% of the total length of the print platen, e.g. about 35%, 40%, or 45% of the total length of the print platen. The length of the media output zone is about 40% to 65% of the total length of the print platen, e.g. about 45%, 50%, or 55% of the total length of the print platen. The total length of the print platen is about 100 mm to about 500 mm, e.g. about 250 mm, 350 mm, or 450 mm.
The sinkhole strategy in the interplaten areas is again different and shall be explained in further detail and with reference to
One example of the geometry and dimensioning of the sinkholes is indicated below:
Having regard to the diameter of the through holes in the print platen module 12, it again may be differentiated between belt areas 50 and non-belt areas 52 and further it may be differentiated between the print zone, media input zone and media output zone.
Within the belt areas 50, for defining the hole diameter, it is taken into account that the holes which are overlapped by the belts could be clogged by a mixture of ink and belt particles, such as dust, due to belt wearing. The maximum concentration of ink is located in the print zone 54 so that the diameter for the through holes which are located in the print zone 54 and the belt area 50 would be largest. The diameters for these holes could be in the range of 1.8 mm to 2.8 mm, e.g. about 2.1 mm, 2.3 mm, or 2.5 mm. On the other hand, the concentration of ink in the media input zone 56 is lower than in the print zone but higher than in the media output zone 58. Accordingly, the hole diameter for the through holes in the media input zone and the media output zone, corresponding to the belt area, may be lower than that in the print zone but still big enough to account for belt wear. Examples of through hole diameters are in the range of 1.5 mm to 2.3 mm, e.g. about 1.8 mm, or 2 mm for the media input zone and in the range of 1.5 mm to 1.8 mm, e.g. about 1.5 mm or 1.7 mm for the media output zone.
In the non-belt areas 52, there is no risk of belt particles clogging the through holes so that the hole diameter can be smaller. In one example, the hole diameter is selected to be in the range of 1.5 mm to 1.8 mm, e.g. about 1.5 mm or 1.7 mm for each of the print zone 54, the media input zone 56 and the media output zone 58. A summary of through hole diameters in the print platen structure according to one example is given by the table below:
The absolute values of through hole diameters, among others, will depend on the type of printing fluid used and on the material of the vacuum belts. It has been shown by experiments that a through hole diameter of less than 1.5 mm in the belt area results in a great part of the holes being clogged. A diameter of 1.5 mm hence is just acceptable for an area of low concentration of ink and belt dust. Starting at diameters of 2 mm and above, clogging becomes less of a problem. At a diameter of e.g. 2.3 mm clogging can be avoided to a large extent. In the non-belt areas, even at a through-hole diameter of only 1.5 mm, holes did not clog, despite of being in the most affected area, such as the print zone. This observation suggests that vacuum belt wear mostly affects clogging.
In one or more examples of the present disclosure, the edge area or interplaten area 52′ of each print platen module is configured differently from the rest of the module so as to provide an interface between the adjacent print platen modules having good vacuum performance and avoiding loss of a vacuum pressure.
In the example shown, except for the interplaten edge area 52′, one through hole is associated with each sinkhole, because it has been found that it usually is sufficient to provide one through hole per sinkhole. However, the present disclosure is not limited to such embodiments and more than one through hole can be associated with one or more sinkholes.
From
In summary, examples of this disclosure provide a print media support assembly and a print platen structure having a good vacuum performance throughout the surface of the print platen. Friction between the print platen and a vacuum belt running across the print platen can be minimized even with high vacuum systems. Further, it is possible to provide very large platen structure for a large format printer without loss of vacuum at platen module interfaces. The print platen structures further is optimized in terms of improving vacuum performance in the area of leading and trailing edges of a print media running across the print platen to obtain an optimum media flatness even when the print medium is fed from a role imparting curling edges. Vacuum performance further can be optimized even when part of the print platen is without a print medium. Also, the effect of friction between the print platen surface and the vacuum belt running across is not only minimized, but it is also balanced between the two conditions that a print platen is covered by a print medium and the print platen is uncovered so as to achieve a stable and smooth a servo drive for driving the vacuum belts. The print platen assembly further is optimized in being insensitive against clogging from printing fluid and vacuum belt wear.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2014/061371 | 6/2/2014 | WO | 00 |