1. Field of the Invention
The present invention relates to a stencil printer for printing an image on a sheet via a master wrapped around a print drum.
2. Description of the Background Art
A thermosensitive stencil for use with a stencil printer has a laminate structure made up of a 1 μm to 8 μm thick, thermoplastic resin film and a porous base adhered to one side of the resin film. The porous base is formed of Japanese paper, synthetic fibers or a mixture thereof.
A digital stencil printer includes a thermal head or similar heating means that perforates, or cuts, the film surface of the stencil with heat in accordance with digital image data representative of a document image. After the perforated stencil,. i.e., a master has been wrapped around a print drum, ink is fed from the inside of the print drum while a press roller or similar pressing member presses a sheet against the print drum. As a result, the ink is transferred from the print drum to the sheet via the perforations of the master.
Assume that the heating means is implemented as a thermal head. Then, a platen roller, which faces the thermal head, is rotated to convey the stencil positioned between the heating surface of the head and the platen roller. Generally, a pressing mechanism presses the thermal head against the platen roller to thereby generate platen pressure, which presses the stencil against the heating surface of the thermal head.
Thermosensitive stencils in general are classified into some different kinds by the thickness of the thermoplastic resin film, the material of the porous base, the kind and the amount of an anti-sticking agent or an antistatic agent coated on the side of the film to be perforated and so forth. Each stencil printer, strictly a master making device included therein, has heretofore been operable only with a particular kind of stencil.
More specifically, when different kinds of stencils are applied to a single master making device, a conveying distance differs from one stencil to another stencil and effects the reproducibility of the size of an image, as well known in the art. This is because slip between the film surface of the stencil and the surface of the thermal head and friction to act between the porous base of the stencil and the platen roller depend on the kind of the stencil. Further, a load to act during perforation due to a master making speed and image density also has influence on the reproducibility of an image size. In addition, the front tension and back tension of the stencil effect the reproducibility of an image size. When such factors are brought out of balance, the stencil conveying distance varies due to changes in slip, friction and load.
The degree of slip varies in accordance with the surface configuration of the thermal head, e.g., the material and smoothness of a protection film and the material of the porous base adhered to the stencil. Other factors that effect slip include the kind and the amount of the anti-sticking agent, antistatic agent or similar overcoat agent coated on the film of the stencil, the material and the amount of a filler contained in the film, and the thickness of the film. The anti-sticking agent promotes slip between the surface of the thermal head and the film while the antistatic agent reduces charging to occur during the conveyance of the stencil.
The degree of friction varies in accordance with the material, surface configuration, rubber hardness and other factors of the platen roller and the kind of the porous support. Other factors that effect friction include the kind and density of the porous base, the kind and the amount of an overcoat agent contained in the base, and the amount of an overcoat agent, which is coated on the film surface, migrated from the film surface to the base when the stencil is rolled up.
A load increases with an increase in image density on a single line and with an increase in master making speed. Further, a load is proportional to the front tension and back tension of the stencil.
When a single master making device conveys a stencil, the thickness of the stencil and the amount of crush of the stencil ascribable to pressure have influence on the conveying distance, too.
Another factor that effects the conveying distance is the environmental conditions. For example, when ambient temperature rises, the diameter of the platen roller increases due to thermal expansion and causes the peripheral speed of the roller to vary. Particularly, when the porous base is hygroscopic, friction to act between the platen roller and the base varies in accordance with humidity and also effects the conveying distance.
The prerequisite with master making is that the thermal head surely perforates the film of the stencil by melting it with heat. Close adhesion between the film surface and the heating elements of the thermal head is one of various factors having influence on the perforation condition. The degree of close adhesion determines a perforation condition and sometimes leaves the film left unperforated. As for the printer body, irregularity in the amounts of heat generated by the heating elements of the thermal head, platen pressure and the surface configuration of the platen roller effect close adhesion.
Specifically, assume that a single master making device with a fixed platen pressure operates with a stencil that cannot be desirably perforated without resorting to high platen pressure and a stencil that can be done so even at low platen pressure. Then, the platen pressure must be matched to the former kind of stencil, but such a platen pressure is excessively high for the latter kind of stencil. The excessive platen pressure causes more than a necessary mechanical stress to act on the thermal head and is not desirable from the standpoint of durability, e.g., wear resistance of the thermal head.
Further, a greater amount of adhesive for adhering the film and porous base must be used when the platen pressure is high than when it is optimum (low); otherwise, the film and base would separate from each other when conveyed between the thermal head and the platen roller. This not only wastes the adhesive, but also adversely effects the perforation condition.
Assume that the same energy is applied to the thermal head when different kinds of stencils are used. Then, the perforation condition sometimes differs and sometimes remains the same, but is not optimum, depending on so-called stencil (film) sensitivity that is determined by the material, thickness and so forth of the film.
To reduce offset particular to a stencil printer, the perforation diameter of the film should preferably be small although the density of a print should be taken into account. However, when porous base has low ink permeability, the perforation diameter of the film must be large enough to transfer a sufficient amount of ink to a sheet; otherwise, the resulting image density would be short.
Master making conditions differ from one kind of stencil to another kind of stencil, as stated above. Therefore, when the user selects a particular kind of stencil by attaching importance to, e.g., image quality or the cost of the stencil itself, the user must vary the various conditions of the master making device one by one in matching relation to the kind of the master. This cannot be done without resorting to expertness or troublesome work. This is why the user has heretofore been obliged to use only a stencil matching with conditions set at the time of delivery.
Technologies relating to the present invention are disclosed in, e.g., Japanese Patent Laid-Open Publication Nos. 11-115145, 11-115148, 6-320851, 8-090747, 9-277686, 11-020983, and 11-091227.
It is an object of the present invention to provide a stencil printer capable of easily, automatically setting master making conditions matching with a desired kind of stencil, and promoting diversification from the user standpoint.
A stencil printer of the present invention perforates, or cuts, a thermosensitive stencil with a thermal head to thereby make a master. The stencil printer includes a stencil distinguishing device for automatically identifying the kind of the stencil or a master setting device for allowing the operator of the printer to set the kind of the stencil. An adjusting device selects, among master making conditions experimentally determined beforehand, a master making condition matching with information output from the stencil distinguishing device or the stencil setting device. The operator can easily change the master making condition in accordance with the kind of a stencil to use.
The above and other objects, features and advantages of the present invention will become more apparent from the following detailed description taken with the accompanying drawings in which:
Referring to
In operation, the operator of the printer lays a document 60 on a document tray, not shown, and then presses a perforation start key not shown. In response, a master discharging step begins. Specifically, a master 61b used for the last printing operation is left on the circumference of the print drum 101.
At the beginning of the master discharging step, the print drum 101 is caused to rotate counterclockwise, as viewed in
The document reading section 80 reads the document in parallel with the master discharging step described above. Specifically, a separator roller 81, a pair of front feed rollers 82a and 82b and a pair of rear feed rollers 83a and 83b in rotation sequentially convey the document 60 in contiguous directions Y2 and Y3, allowing the document reading section 80 to read the document 60. If two or more documents are stacked on the document tray, then a blade 84 cooperates with the separator roller 81 to cause only the bottom document to be paid out from the document tray. A feed roller motor 83A causes the rear feed roller 83a to rotate. The rear feed roller 83a, in turn, drives the front feed roller 82a via a timing belt, not shown, passed over the rollers 83a and 82a. The feed rollers 82b and 83b are driven rollers.
More specifically, while the document 60 is conveyed along a glass platen 85, a fluorescent lamp 86 illuminates the document 60. The resulting imagewise reflection from the document 60 is reflected by a mirror 87 and then incident to a CCD (Charge Coupled Device) image sensor or similar image sensor 89 via a lens 88. The document reading section 80 is so configured as to read the document 60 with a conventional reduction system. The document 60 fully read is driven out to a tray 80A. An electric signal output from the image sensor or photoelectric transducer 89 is input to an analog-to-digital (AD) converter, not shown and converted to digital image data thereby.
The master making section 90 executes a master making and feeding step in parallel with the image reading operation in accordance with the digital image data. Specifically, A thermosensitive stencil 61 is paid out from a roll and set at a preselected position in the master making device 90. A platen roller presses the stencil 61 against a thermal head or heating means 30. The platen roller 92 and rollers 93a and 93b are rotated to intermittently convey the stencil 61 to the downstream side. A platen motor 26 drives the platen roller 92. A number of fine heating elements are arranged in an array on the thermal head 30 in the main scanning direction. The heating elements selectively generate heat in accordance with the digital image data output from the AD converter. As a result, a thermosensitive resin film included in the stencil 61 and contacting the heating elements generating heat is perforated, or cut, by the heat. In this manner, the image data is written in the stencil 61 in the form of a perforation pattern.
A pair of master feed rollers 94a and 94b convey the leading edge of the perforated part of the stencil 60, i.e., a master 61a toward the circumference of the print drum 101. A guide, not shown, steers the leading edge of the master 61a downward and causes it to hang down toward a master damper 102, which is mounted on the print drum 101 and held in an open position as indicated by a phantom line in
The master damper 102 clamps the leading edge of the master 61a at a preselected timing. The print drum 101 then rotates clockwise, as indicated by an arrow A in
A printing step begins after the master making and feeding step. Specifically, the sheet feeder 110 includes a sheet tray 51 loaded with a stack of sheets 62. A pickup roller 111 and a pair of separator rollers 112a and 112b pay out the top sheet 62 from the sheet tray 51 toward a pair of registration rollers 113a and 113b in a direction indicated by an arrow Y4 in
The print drum 101 has thereinside an ink feed tube 104 that plays the role of the shaft of the drum 101 at the same time. Ink drops from the ink feed tube 104 into an ink well 107 formed between an ink roller 105 and a doctor roller 106. The ink roller 105 contacts the inner circumference of the print drum 101 and rotates in the same direction as and in synchronism with the print drum 101, feeding the ink to the inner circumference of the drum 101. The ink is a W/O type emulsion ink.
A peeler 114 peels off the sheet 62 on which the image is printed from the print drum 101. A belt 117 is passed over an inlet roller 115 and an outlet roller 116 and conveys the sheet 62 to the sheet discharging section 130, as indicated by an arrow Y5 in
Subsequently, the operator inputs a desired number of prints on numeral keys, not shown, and then presses a print start key not shown. In response, the procedure described above is repeated in the same manner a number of times corresponding to the number of desired prints.
As shown in
As shown in
A relation between the kind of the master 61 and the feed speed of the platen motor 26, which causes the platen motor 26 to rotate at a speed adequate for the kind of the master 61, is experimentally determined beforehand with the actual master making device 90. The rotation speed of the platen roller 92 determines a master conveying speed. The ROM mentioned earlier stores data representative of the above relation, i.e., a master making condition. The control means 150A reads adequate one of platen motor feed speeds out of the ROM in accordance with the kind of the stencil 61 identified by the stencil distinguishing means 152 and sets the adequate speed. This successfully maintains a distance over which the stencil 61 is conveyed constant without regard to the kind of the stencil 61, thereby insuring the reproducibility of the size of an image.
Alternatively, a chip or similar miniature capacitor may be provided on the stencil 61 or the core 156 as means to be sensed, in which case a capacity sensor will be mounted on the apparatus body as sensing means. The capacity sensor determines the kind of the stencil 61 in terms of capacity. This capacity scheme maybe replaced with a resistance scheme. Specifically, a chip or similar miniature resistor may be provided on the stencil 61 or the core 156 as means to be sensed, in which case a resistor sensor will be mounted on the apparatus body as sensing means. The resistor may even be implemented as a tape or a sheet having resistance and adhered to one end or the inner periphery of the core 156.
Generally, assume that use is made of a stencil with low perforation sensitivity, e.g., one having great thickness for a given kind of a film. Then, it is necessary to increase energy to be applied to a thermal head. It follows that if the maximum width of pulses is fixed, then a voltage to be applied to the thermal head must be raised. This, however, shortens the service life of the thermal head. Although the pulses may be caused to overlap each other, this kind of scheme enhances heat accumulation and is not feasible for high-speed master making. More specifically, accumulated heat increases the diameter of a perforation more than expected, aggravates offset particular to a stencil printer, and degrades resistance to printing, image size reproducibility and so forth.
During perforation, the contraction stress of a thermoplastic resin film acts in a direction in which the diameter of a perforation increases. If the master making speed is low, i.e., if the writing period is long, then pressure exerted by a platen roller limits the contraction stress. This, coupled with the fact that the heat accumulation of the thermal head decreases, makes the perforation diameter smaller than a perforation diameter available at a standard master making speed. Conversely, if the master making speed is high, i.e., if the writing period is short, then a perforation is released from the pressure of the platen roller at a high speed and causes the contraction stress to sufficiently act. In addition, the heat accumulation of the thermal head is enhanced and increases the diameter of a perforation.
A relation between the kind of the master 61 and the master making speed adequate for the kind of the master 61 is experimentally determined beforehand with the actual master making device 90. A ROM included in control means 150B stores data representative of the above relation, i.e., a master making condition. For example, when the perforation sensitivity of the stencil is low, data indicative of a mater making speed as low as, e.g., 3.0 ms/line is selected. When the perforation sensitivity is standard one, data indicative of a standard master making speed, e.g., 1.5 ms/line is selected. In this manner, the master making speed is selected stepwise in accordance with the perforation sensitivity of a stencil.
As shown in
Reference will be made to
As shown in
The DC motor 172 causes the spring 168 to expand or contract. The spring 168, in turn, varies pressure acting between the thermal head 30 and the thermoplastic resin film of the stencil 61, i.e., platen pressure. The control means 150C controls the rotation angle or rotation stop position of the DC motor 172 in accordance with the output of each optical sensor 176.
In the illustrative embodiment, the control means 150C interrupts the rotation of the DC motor 172 when the feeler 174 reaches the position of either one of the optical sensors 176 and interrupts its optical path. This allows the platen pressure to be adjusted in two steps. Three or more optical sensors 176 maybe used to adjust the platen pressure in three or more steps, if desired. Alternatively, the outputs of the optical sensors 176 and the rotation angle of a motor (DC motor or a stepping motor) may be used to set the platen pressure at a location other than the optical sensors 176. A cam with a particular contour, not shown, selectively cancels the contact between the heating elements of the thermal head 30 and the thermoplastic resin film of the stencil 61.
To adjust the length of the spring 168, use may be made of a reflection type sensor, e.g., a magnetic or an optical encoder responsive to a rotation angle. Further, the DC motor 172 may be replaced with a pulse motor.
A relation between the kind of the master 61 and the rotation angle or rotation stop position of the DC motor 172, which implements platen pressure adequate for the kind of the master 61, is experimentally determined beforehand with the actual master making device 90. A ROM included in the control means 150C stores data representative of the above relation, i.e., a master making condition. The control means 150C selects a rotation angle of the DC motor 172 matching with the kind of the stencil 61 determined by the stencil distinguishing means 152 and sets it as a master making condition. This prevents the platen pressure from excessively rising and increasing the mechanical stress of the thermal head 30 without regard to the kind of the stencil 61.
As shown in
Alternatively, the motor or drive source 26 that drives the platen roller 92 may be used to vary the pressure acting between the feed rollers 93a and 93b. Further, a gear ratio may be varied to adjust the front tension of the stencil 61.
As shown in
The back tension of the stencil 6, like the front tension, effects the reproducibility of the image size. Reference will be made to
Alternatively, the motor or drive source 26 that drives the platen roller 92 may be used to vary the pressure acting between the feed rollers 190a and 190b. Further, a gear ratio may be varied to adjust the front tension of the stencil 61.
As shown in
The illustrative embodiments described so far include the motor 26 for driving the platen roller 92 each. Alternatively, the rollers 93a and 93b described in relation to the front tension may be used and controlled as a drive source for conveying the stencil 61, in which case the platen roller 92 will be driven by the above drive source.
Generally, when use is made of a stencil of the kind that can be accurately perforated, it is possible to reduce the size of perforations to be formed in the film of the stencil in a defect-free condition. This is effective to reduce, e.g., sticking when an image with a high image ratio is to be formed in the stencil, thereby enhancing accurate reproduction of an image size.
As for a relation between the perforation of the film (perforation area) and sticking (stencil contraction ratio), the sticking level rises with an increase in the perforation size of the film. In light of this, Japanese Patent Laid-Open Publication Nos. 11-115145 and 11-115148 mentioned earlier each disclose a particular scheme for controlling perforation energy in accordance with the print ratio. Adequate energy applied to the stencil extends the life of the thermal head 30 and saves energy at the same time.
A relation between the kind of the stencil 61 and the pulse width (pulse width for feeding current to each heating element of the thermal head 30) adequate for the kind of the stencil 61 is experimentally determined beforehand with the actual master making device 90. A ROM included in the control means 150F stores data representative of the above relation, i.e., a master making condition. While the pulse width may be selected in the same manner as in Laid-Open Publication No. 11-115145 or 11-115148, the illustrative embodiment selects it by taking account of the perforation ability of the stencil and the ink permeability of the porous base as well.
The control means 150F selects an adequate pulse width in accordance with the kind of the stencil 61 identified by the stencil distinguishing means 152 as a master making condition. Consequently, image quality matching with the kind of the stencil 61 is achievable.
Reference will be made to
As shown in
As shown in
The illustrative embodiment may additionally take account of the kind and temperature of the ink for further promoting more practical, accurate energy control. Further, the illustrative embodiment additionally execute conventional thermal history control, common drop correction control and so forth, if desired.
As shown in
Any one of the embodiments shown and described may sense any other environmental condition, e.g., humidity in addition to temperature.
The foregoing embodiments each control only one of the master making speed, master conveying speed, platen pressure, energy and so forth. Such different control procedures should preferably be executed in series so as to further promote accurate control, as will be described specifically with reference to
After the step S4, a master making speed matching with the stencil A is selected (step S5), and then a feed speed of the platen motor S26 matching with the stencil A is selected (step S6). Subsequently, the platen roller 26 is driven at the feed speed selected (step S7). Thereafter, energy to be applied to the thermal head 30 and adequate for the stencil A is selected (step S8). After the step S8, a master making operation begins (step S9). After the master making operation, the platen motor 26 is caused to stop rotating (step S1). This is followed by the feed of a master to the print drum 101 (step S12) and then followed by a printing operation (step S13).
Assume that the stencil is determined to be a stencil B in the step S2. Then, the control means 150 selects the rotation angle of the DC motor 172 matching with the stencil B out of the ROM (step S14) and sets the associated platen pressure as one of master making conditions (step S15). The control means 150 then selects a master feeding speed adequate for the stencil B (step S16), selects the feed speed of the platen motor 26 adequate for the stencil B (step S17), and then drives the platen roller 26 (step S18). Thereafter, the control means 150 selects energy adequate for the stencil (step S19) and then causes a master making operation to start (step S20). On the completion of the master making operation (step S21), the control means 150 causes the platen motor 26 to stop rotating (step S22), starts feeding the master to the print drum 101 (step S12), and then executes a printing operation (step S13).
As stated above, the first to thirteenth embodiment have various unprecedented advantages, as enumerated below.
(1) Master making conditions matching with the kind of a stencil used are automatically set without resorting to expertness or troublesome work. The master making conditions set obviate manual operation even when the kind of the stencil is changed. This is desirable from the diversification and user standpoint.
(2) A distance over which the stencil is to be conveyed remains constant without regard to the kind of the stencil, so that the size of an image can be accurately reproduced.
(3) The influence of a difference in perforation sensitivity brought about by the replacement of the stencil is obviated. This insures desirable reproducibility of the size of an image while preventing the life of a thermal head from being shortened.
(4) Excessive platen pressure ascribable to the replacement of the stencil is obviated, so that the life of the thermal head is extended.
(5) The reproducibility of the size of an image is free from the influence of short or excessive front tension or that of excessive or short back tension.
(6) Image quality matching with the kind of the stencil is achievable.
(7) As soon as the stencil in the form of a master is set, it is possible to identify the kind of the stencil easily and accurately.
Other embodiments of the control system in accordance with the present invention will be described hereinafter. In the embodiments to be described, structural elements identical with the previous embodiments are designated by identical reference numerals and will not be described specifically.
Referring to
The embodiments to be described after the illustrative embodiments also include the stencil setting means 152 each.
As shown in
The control means 150A′ includes a ROM. A relation between the kind of the master 61 and the feed speed of the platen motor 26, which causes the platen roller 92 to rotate at a speed adequate for the kind of the stencil 61, is experimentally determined beforehand with the actual master making device 90. Again, the rotation speed of the platen roller 92 determines a master conveying speed. The ROM stores data representative of the above relation, i.e., a master making condition. The control means 150A′ reads adequate one of platen motor feed speeds out of the ROM in accordance with the kind of the stencil 61 input on the stencil setting means 152 and sets the adequate speed. This successfully maintains a distance over which the stencil 61 is conveyed constant without regard to the kind of the stencil 61, thereby insuring the reproduction of an image with a constant size.
A relation between the kind of the master 61 and the master making speed adequate for the kind of the master 61 is experimentally determined beforehand with the actual master making device 90. The ROM of the control means 150B′ stores data representative of the above relation, i.e., a master making condition. For example, when the perforation sensitivity of the stencil is low, data indicative of a mater making speed as low as, e.g., 3.0 ms/line is selected. When the perforation sensitivity is standard sensitivity, data indicative of a standard master making speed, e.g., 1.5 ms/line is selected. In this manner, the master making speed is selected stepwise in accordance with the perforation sensitivity of a stencil.
As shown in
Reference will be made to
In the illustrative embodiment, a relation between the kind of the master 61 and the rotation angle or rotation stop position of the DC motor 172, which implements a platen pressure adequate for the kind of the master 61, is experimentally determined beforehand with the actual master making device 90. A ROM included in the control means 150C′ stores data representative of the above relation, i.e., a master making condition. The control means 150C′ selects a rotation angle of the DC motor 172 matching with the kind of the master 61 input on the stencil setting means 152 and sets it as a master making condition. This prevents the platen pressure from excessively rising and increasing the mechanical stress of the thermal head 30 without regard to the kind of the stencil 61.
The back tension of the stencil 6, like the front tension, effects the reproducibility of the image size, as stated previously. Reference will be made to
The illustrative embodiments described so above include the motor 26 for driving the platen roller 92 each. Alternatively, the rollers 93a and 93b described in relation to the front tension may be used and controlled as a drive source for conveying the stencil 61, in which case the platen roller 92 will be driven by the above drive source.
In the illustrative embodiment, a relation between the kind of the stencil 61 and the pulse width (pulse width for feeding current to each heating element of the thermal head 30) adequate for the kind of the stencil 61 is experimentally determined beforehand with the actual master making device 90. A ROM included in the control means 150F′ stores data representative of the above relation, i.e., a master making condition. Again, while the pulse width may be selected in the same manner as in Laid-Open Publication No. 11-115145 or 11-115148 mentioned earlier, the illustrative embodiment selects it by taking account of the perforation ability of the stencil and the ink permeability of the porous support as well.
The control means 150F′ selects an adequate pulse width in accordance with the kind of the stencil 61 input on the stencil setting means 152 as a master making condition. Consequently, image quality matching with the kind of the stencil 61 is achievable.
Reference will be made to
The illustrative embodiment may also additionally take account of the kind and temperature of the ink for further promoting more practical, accurate energy control. Further, the illustrative embodiment additionally executes conventional thermal history control, common drop correction control and so forth, if desired.
As shown in
Again, the illustrative embodiments shown and described each may sense any other environmental condition, e.g., humidity in addition to temperature.
The fourteenth to twenty-seventh embodiments each control only one of the master making speed, master conveying speed, platen pressure, energy and so forth. Such different control procedures should preferably be executed in series so as to further promote accurate control, as will be described specifically with reference to
As stated above, the fourteenth to twenty-seventh embodiments each include the stencil setting means implemented as an LCD and keys arranged on the operation panel of the printer body. The stencil setting means therefore does not increase the overall size of the printer or makes circuitry sophisticated. Alternatively, the stencil setting means may be implemented as, e.g., a personal computer or similar host connected to the printer body, enhancing easy operation and diversification. The above illustrative embodiments, of course, achieve the advantages described with reference to the first to thirteenth embodiments as well.
Various modifications will become possible for those skilled in the art after receiving the present disclosure without departing from the scope thereof.
Number | Date | Country | Kind |
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2000-340674 | Nov 2000 | JP | national |
2000-341969 | Nov 2000 | JP | national |
Number | Date | Country | |
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Parent | 09986281 | Nov 2001 | US |
Child | 10898331 | Jul 2004 | US |