Digital printing system with sheet conveyor having rotation element to prevent damage to sheet

Abstract

To provide a substrate transport assembly that prevents unwanted friction and damage to an ink image printed on the surface of a sheet facing the substrate transport assembly.SOLUTION: A system (10) includes an intermediate transfer member (ITM) (44) and a substrate conveyor (80). The ITM is configured to receive one or more droplets of printing fluid on a surface thereof to form an image and to transfer the image to a target substrate (50). The substrate conveyor is configured to hold the target substrate and move the same to and from the ITM for image transfer, the substrate conveyor includes one or more rotation elements that provide mechanical support to the target substrate such that, when the target substrate moves over one or more rotation elements, at least one of the rotation elements rotates in response to physical contact with the target substrate.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates generally to digital printing systems, and more particularly to a method and system for preventing damage to print substrates in a printing system. [Background technology]

[0002] Various methods and systems are known in the art for handling substrates and preventing abrasion and surface damage.

[0003] For example, U.S. Patent Application Publication No. 2018 / 0229516 describes an inkjet printing device including a vacuum bed table configured to support a large, flat substrate against the vacuum bed table at a hold-down area by application of a vacuum force. The inkjet printing device further includes a removable flat substrate support device configured to support the large, flat substrate against the vacuum bed table at a hold-down area during printing, and a vacuum belt coupled to a plurality of pulleys and wrapped around the vacuum bed table. The vacuum bed table is configured to couple the removable flat substrate support device, which is stationary against the vacuum bed table by application of a vacuum force, and the vacuum belt is sandwiched between the removable flat substrate support device and the vacuum bed table.

[0004] No. 7,284,479 describes a stencil printer operable in a duplex printing mode. The stencil printer prints an image on one side of a sheet and then prints another image on the reverse side of the same sheet. The printer includes at least one printing drum and at least one press roller facing the printing drum to press the sheet against the printing drum. When the press roller is used to press the reverse side of the sheet against the printing drum, it is implemented as an elastic body provided with a fluorine compound layer on its surface.

[0005] No. 4,786,045 describes a registration mechanism for offsetting a paper set against a registration edge that is alternately inboard and outboard in position. The paper sheet is urged against the registration edge using two rotating urethane paddles located relatively close to the registration edge, but the sheet is prevented from developing excessive angular velocity by two restraining means located relatively far from the registration edge in the form of Teflon balls held in cages that allow the balls to move vertically and rotationally while preventing them from moving laterally.

[0006] No. 5,096,291 describes a positioning system for positioning a part or element at various inclinations relative to a plane perpendicular to a central axis and for rotating the part about the central axis. A holder supporting the part is free to pivot about a point on the central axis. A central spindle on the axis is coupled to a concentric tiltable ring assembly controllable in two free directions from an input device.

[0007] No. 3,764,188 describes anti-friction bearings made by replacing one or more of the conventional roller elements with TFE or FEP elements of the same size and shape. After a short break-in period, a thin anti-friction film or TFE or FEP is transferred to the races and other bearing elements and is maintained throughout the life of the bearing with additional transfer from the fluoroplastic roller elements to prevent the surface coating from wearing off.

[0008] PCT International Publication No. WO 2005 / 037691 describes a free ball bearing that includes a body having a hemispherical concave surface, a number of small balls disposed on the hemispherical concave surface of the body, a large ball mounted on the number of small balls, and a lid that prevents the large and small balls from being pushed out. Summary of the Invention

[0009] Embodiments of the invention described herein provide a system that includes an intermediate transfer member (ITM) and a substrate conveyor. The ITM is configured to receive one or more droplets of printing fluid to form an image on a surface thereof and transfer the image to a target substrate. The substrate conveyor is configured to grip and move the target substrate to and from the ITM for transfer of the image, and the substrate conveyor includes one or more rotating elements configured to provide mechanical support to the target substrate such that as the target substrate moves over the one or more rotating elements, at least one of the rotating elements is configured to rotate in response to physical contact with the target substrate.

[0010] In some embodiments, at least one of the rotating elements is mounted on an axle. In other embodiments, the substrate conveyor has one or more slots configured to receive the axle at a first angle and engage the axle at a second angle. In yet other embodiments, the substrate conveyor moves the target substrate along a first direction and the axle lies along a second direction perpendicular to the first direction.

[0011] In an embodiment, the axis is shared by two or more of the rotating elements. In another embodiment, at least one of the rotating elements has a shape selected from the list consisting of a ball and a cylinder. In yet another embodiment, at least one of the rotating elements comprises an ink repellent material.

[0012] In some embodiments, the ink repellent material comprises polytetrafluoroethylene (PTFE). In other embodiments, the rotating elements are arranged in one or more arrays. In yet other embodiments, the substrate conveyor comprises a frame configured to secure the rotating elements at respective positions in the one or more arrays.

[0013] In embodiments, at least one of the rotating elements is mounted on an axle and the frame is configured to fix the axle at one of the respective positions. In other embodiments, one or more of the arrays of rotating elements are fitted along a curved surface. In yet other embodiments, the substrate conveyor includes a perforated plate having a number of openings and the movable elements are fitted into each opening. In some embodiments, the perforated plate is curved. In other embodiments, the rotating elements are configured to at least prevent damage to a surface of the target substrate that is in physical contact with one or more of the rotating elements. In yet other embodiments, the surface of the target substrate that is in physical contact with one or more of the rotating elements includes an image.

[0014] According to an embodiment of the invention, there is further provided an apparatus for assembly to a substrate conveyor of a digital printing system, the apparatus including one or more rotating elements and a mounting element. The one or more rotating elements are configured to provide mechanical support to a target substrate such that at least one of the rotating elements is configured to rotate in response to physical contact with the target substrate as the target substrate moves along the substrate conveyor over the one or more rotating elements. The mounting element is configured to secure the one or more rotating elements at one or more respective positions.

[0015] In some embodiments, the surface of the target substrate that is in physical contact with one or more of the rotating elements includes an image formed by a digital printing system, hi other embodiments, the rotating elements are arranged in one or more arrays, and the one or more arrays are configured to match the shape of the mounting element.

[0016] According to an embodiment of the invention, there is further provided a method including providing one or more rotating elements for mechanically supporting a target substrate such that at least one of the rotating elements rotates in response to physical contact with the target substrate as the target substrate moves over the one or more rotating elements, the one or more rotating elements being fixed at one or more respective positions of the mounting elements, the mounting elements being assembled to a substrate conveyor of a digital printing system.

[0017] In embodiments, assembling the attachment element includes assembling the attachment element to the substrate conveyor during manufacture of the digital printing system. In other embodiments, assembling the attachment element includes assembling the attachment element to the substrate conveyor of the digital printing system after manufacture of the digital printing system is completed. In yet other embodiments, assembling the attachment element includes assembling the attachment element to the substrate conveyor of the digital printing system after the digital printing system is installed at a print facility.

[0018] According to an embodiment of the invention, there is further provided a method including forming an image by receiving one or more droplets of printing fluid at an intermediate transfer member (ITM) and transferring the image to a target substrate, the target substrate being gripped and moved to and from the ITM for transfer of the image and for moving the target substrate over one or more arrays of rotating elements that provide mechanical support to the target substrate, at least one of the rotating elements rotating in response to physical contact with the target substrate as the target substrate moves over the one or more arrays.

[0019] According to an embodiment of the present invention, there is further provided a system including an intermediate transfer member (ITM) and a substrate conveyor. The ITM is configured to receive one or more droplets of printing fluid to form an ink image on the surface and transfer the ink image to a target substrate. The substrate conveyor is configured to move the target substrate to and from the ITM for transfer of the image and includes a moving gripper and one or more arrays of rotating elements. The moving gripper is configured to grip and move the target substrate. The one or more arrays of rotating elements are configured to provide mechanical support to the target substrate, and at least one of the rotating elements is configured to rotate in response to physical contact with the target substrate as the gripper moves the target substrate over the one or more arrays.

[0020] According to an embodiment of the invention, there is further provided a method including forming an ink image by receiving one or more droplets of printing fluid at an intermediate transfer member (ITM) and transferring the ink image to a target substrate, wherein the target substrate is moved to and from the ITM by gripping and moving the target substrate over one or more arrays of rotating elements that provide mechanical support to the target substrate to transfer the image, at least one of the rotating elements rotating in response to physical contact with the target substrate as the target substrate moves over the one or more arrays.

[0021] According to an embodiment of the present invention, there is further provided a system including an imaging station and a substrate conveyor. The imaging station is configured to apply droplets of one or more printing fluids to a target substrate to form an image on the substrate. The substrate conveyor is configured to grip and move the target substrate to and from the imaging station to form an image thereon, the substrate conveyor including one or more rotating elements configured to provide mechanical support to the target substrate, at least one of the rotating elements configured to rotate in response to physical contact with the target substrate as the target substrate moves over the one or more rotating elements.

[0022] The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken in conjunction with the drawings in which: [Brief description of the drawings]

[0023] [Figure 1] 1 is a schematic side view of a digital printing system according to an embodiment of the present invention. [Figure 2A] 1 is a schematic, pictorial representation of a substrate transport assembly mounted to a substrate conveyor of a digital printing system in accordance with an embodiment of the present invention. [Figure 2B] 2 is a schematic, pictorial illustration of a plate of a substrate transport assembly, in accordance with an embodiment of the present invention; [Diagram 3] 1A-1D are schematic diagrams illustrating a process sequence for assembling a rotating ball to an array of rotating elements according to an embodiment of the present invention. [Figure 4A] FIG. 2 is a schematic side view of a rotating ball and a shaft fixed to a plate according to an embodiment of the present invention. [Figure 4B] FIG. 2 is a schematic side view of a rotating ball and a shaft fixed to a plate according to an embodiment of the present invention. [Diagram 5] 11 is a schematic pictorial diagram of a rolling ball mounted on a frame in accordance with another embodiment of the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] Overview Some printing systems are designed to print an image on one or both sides of a substrate and then transport the printed substrate to an output tray. For double-sided printed substrates in particular, it is important to prevent surface damage, e.g., scratches, when the substrate is transported between the printing process and to the output tray.

[0025] The embodiments of the present invention described below provide improved techniques for transporting a printing substrate through a printing press while eliminating, or at least minimizing, possible damage to an image printed on the substrate.

[0026] In some embodiments, the digital printing system includes an intermediate transfer member (ITM) and a substrate conveyor. The ITM is configured to receive ink droplets from an imaging station to form an ink image on the ITM and transfer the ink image to a target substrate, such as a sheet of paper. The substrate conveyor is configured to move the target substrate (e.g., a sheet of paper) from an input stack along a transfer station where the ink image is transferred from the ITM to the substrate, and to an output tray after image transfer to the sheet of paper is complete.

[0027] In some embodiments, the substrate conveyor comprises a moving gripper configured to grip the paper sheet and move it along a perforated plate coupled to a chain delivery of the printing system, hi some embodiments, the substrate conveyor further comprises an array of rolling elements, e.g., polytetrafluoroethylene (PTFE) balls, mounted on each shaft.

[0028] In some embodiments, the ball is secured in an opening in a perforated plate such that the ball surface protrudes from the plate surface and provides mechanical support to the paper sheet.

[0029] In some embodiments, as the gripper moves the paper sheet over the array, the ball is configured to rotate in response to physical contact between the ball and the surface of the opposing paper sheet, such that there is minimal friction between the ball and the paper sheet, and the ball comprises an ink repellent material, so that no damage occurs to the surface of the paper sheet being transported.

[0030] In some embodiments, both the chain delivery and the perforated plate may have a curved portion, and the balls of the array are fitted along the respective curved surfaces of the plates. In these embodiments, the balls are configured to provide mechanical support and rotate without damaging the surface of the paper sheet as the gripper moves the paper sheet along the curved surface.

[0031] The disclosed techniques are useful for improving the quality of printed substrates and preventing scratches, especially in duplex printing where the image is printed on the surface of the substrate that is in physical contact with the substrate conveyor. System Description

[0032] 1 is a schematic side view of a digital printing system 10 according to an embodiment of the present invention. In some embodiments, the system 10 includes an image forming station 60, a drying station 64, impression stations 84 and 92, and a rotating flexible blanket 44 that cycles through a blanket treatment station 52.

[0033] In the context of this invention and the claims, the terms "blanket" and "intermediate transfer member (ITM)" are used interchangeably and refer to a flexible member comprising one or more layers used as an intermediate member configured to receive an ink image and transfer the ink image to a target substrate, as described in more detail below.

[0034] In an operational mode, imaging station 60 is configured to form a mirror ink image, also referred to herein as an “ink image” (not shown), of digital image 42 on an upper run on the surface of blanket 44. The ink image is then transferred to a target substrate (e.g., paper, folding carton, and any suitable flexible packaging in sheet or continuous web form) located beneath the lower run of blanket 44.

[0035] In the context of this disclosure and in the claims, the terms "ink image" and "image" are used interchangeably and refer to the printed image formed on blanket 44 and transferred to a target substrate.

[0036] In the context of the present invention, the term "run" refers to the length or section of blanket 44 between any two given rollers over which blanket 44 is guided.

[0037] In some embodiments, during installation, the blanket 44 may be bonded (e.g., spliced) end-to-end to form a continuous blanket loop (not shown). Exemplary methods and systems for splice installation are described in detail in U.S. Provisional Patent Application No. 62 / 532,400, the disclosure of which is incorporated herein by reference.

[0038] In some embodiments, imaging station 60 generally comprises a number of print bars 62, each mounted (e.g., with a slider) to a frame (not shown) that is positioned at a fixed height above the surface of the upper run of blanket 44. In some embodiments, each print bar 62 comprises a strip of print heads as wide as the print area on blanket 44, with individually controllable print nozzles.

[0039] In some embodiments, imaging station 60 may include any suitable number of bars 62, and each bar 62 may include a printing fluid, such as, for example, a different colored water-based ink. The inks typically have visible colors, such as, but not limited to, cyan, magenta, red, green, blue, yellow, black, and white. In the example of FIG. 1, imaging station 60 includes seven print bars 62, but may also include four print bars 62 having any selected color, such as, for example, cyan, magenta, yellow, and black.

[0040] In some embodiments, the print heads are configured to eject ink droplets of various colors onto the surface of blanket 44 to form an ink image (not shown) on the surface of blanket 44 .

[0041] In some embodiments, the various print bars 62 are spaced apart from one another along the axis of blanket 44 movement, represented by arrow 94. In this configuration, precise spacing between print bars 62 and synchronization of the ink drop direction of each bar 62 with the movement of blanket 44 is important to enable accurate placement of the image pattern.

[0042] In some embodiments, the system 10 includes a heater, such as a hot gas or air blower 66 positioned between the print bars 62 and configured to partially dry the ink droplets deposited on the surface of the blanket 44.

[0043] This hot air flow between the print bars can help, for example, to reduce condensation on the surface of the print head and / or to deal with splatter (e.g., residue or small droplets dispersed around the main ink droplet) and / or to prevent clogging of the inkjet nozzles of the print head and / or to prevent ink droplets of different colors on the blanket 44 from undesirably blending with one another. In some embodiments, the system 10 includes a drying station 64 configured to blow hot air (or other gas) onto the surface of the blanket 44. In some embodiments, the drying station includes a blower 68 or any other suitable drying device.

[0044] At drying station 64, the ink image formed on blanket 44 is exposed to radiation and / or hot air to more completely dry the ink and evaporate most or all of the liquid carrier, leaving only a layer of resin and colorant that is heated to the point of becoming a highly viscous ink film.

[0045] In some embodiments, system 10 includes a blanket transport assembly 70 configured to move a rotating ITM, such as, for example, blanket 44. In some embodiments, blanket transport assembly 70 includes one or more rollers 78, at least one of which includes an encoder (not shown) configured to record a position of blanket 44 to control the position of a portion of blanket 44 relative to a respective print bar 62. In some embodiments, the encoder of roller 78 generally includes a rotary encoder configured to generate a rotation-based position signal indicative of the angular displacement of the respective roller.

[0046] Additionally or alternatively, blanket 44 may include an integrated encoder (not shown) for controlling the operation of various modules of system 10. Integrated encoders are described in detail, for example, in U.S. Provisional Patent Application No. 62 / 689,852, the disclosure of which is incorporated herein by reference.

[0047] In some embodiments, blanket 44 is guided over rollers 76 and 78, and a motorized tension roller, also referred to herein as dancer 74. Dancer 74 is configured to control the length of slack in blanket 44, the movement of which is represented diagrammatically by a double-headed arrow.

[0048] Additionally, stretching of blanket 44 over time does not have any effect on the ink image placement performance of system 10, but simply requires that tension dancer 74 take up more slack.

[0049] In some embodiments, dancer 74 may be motorized. The configuration and operation of rollers 76 and 78 and dancer 74 are described in further detail, for example, in U.S. Patent Application Publication No. 2017 / 0008272 and the above-referenced PCT International Publication No. WO 2013 / 132424, the disclosures of which are incorporated herein by reference in their entireties.

[0050] In some embodiments, the system 10 includes an impression station 84 where the blanket 44 passes between an impression cylinder 82 and a pressure cylinder 90 configured to convey the compressible blanket.

[0051] In some embodiments, system 10 includes a control console 12 configured to control multiple modules and assemblies of system 10, such as a blanket transport assembly 70, an image forming station 60 located above the blanket transport assembly 70, and a substrate conveyor 80 located below the blanket transport assembly 70, which will be described in more detail below.

[0052] In some embodiments, the console 12 includes a processor 20, typically a general purpose computer, with appropriate front end and interface circuitry for interfacing with and receiving signals from a controller 54 via a cable 57. In some embodiments, the controller 54, shown generally as a single device, may include one or more electronic modules attached to the system 10 at a predetermined location. At least one of the electronic modules of the controller 54 may include electronic devices, such as, for example, control circuits or a processor (not shown), configured to control the various modules and stations of the system 10.

[0053] In some embodiments, the processor 20 and control circuitry may be programmed in software to perform functions used by the printing system and store data related to the software in memory 22. The software may be downloaded to the processor 20 and control circuitry in electronic form, for example over a network, or may be provided on a non-transitory tangible medium, such as, for example, an optical, magnetic, or electronic memory medium.

[0054] In some embodiments, the console 12 includes a display 34 configured to display data and images received from the processor 20, or input inserted by a user (not shown) using an input device 40. The configuration of the console 12 is provided by way of example and is simplified for conceptual clarity. In other embodiments, the console 12 may have any other suitable configuration, for example, alternative configurations of the console 12 are described in detail in U.S. Pat. No. 9,229,664, the disclosure of which is incorporated herein by reference.

[0055] In some embodiments, the processor 20 is configured to display on the display 34 a digital image 42 having one or more segments (not shown), and possibly various types of test patterns stored in the memory 22 .

[0056] In some embodiments, the blanket treatment station 52, also referred to herein as a cooling station, is configured to treat the blanket, for example, by cooling the blanket and / or applying a treatment fluid to the outer surface of the blanket 44 and / or cleaning the outer surface of the blanket 44. In the blanket treatment station 52, the temperature of the blanket 44 may be reduced to a desired value before the blanket 44 enters the imaging station 60. This treatment may be performed by passing the blanket over one or more rollers or blades configured to cool and / or clean and / or apply a treatment fluid to the outer surface of the blanket.

[0057] In some embodiments, processor 20 is configured to receive a signal indicative of the surface temperature of blanket 44, e.g., from a temperature sensor (not shown), to monitor the temperature of blanket 44 and control operation of blanket treatment station 52. Examples of such treatment stations are described, e.g., in PCT International Publication Nos. WO 2013 / 132424 and WO 2017 / 208152, the disclosures of which are incorporated herein by reference in their entireties. Additionally or alternatively, system 10 is configured to apply treatment fluid to the ITM by jetting or any other technique prior to ink jetting at the imaging station.

[0058] In the example of FIG. 1, station 52 is mounted between roller 78 and roller 76, however, station 52 may be mounted adjacent blanket 44 at any other suitable location between impression station 84 and image-forming station 60.

[0059] In some embodiments, impression cylinder 82 of impression station 84 is configured to press an ink image onto a target substrate, such as, for example, an individual sheet 50. In some embodiments, the target substrate may comprise any suitable substrate, such as, for example, but not limited to, a flexible substrate, a partially flexible substrate (e.g., having a flexible portion and a rigid portion), or a rigid substrate.

[0060] 1, roller 78 is located on the upper run of blanket 44 and is configured to maintain tension on blanket 44 as it passes adjacent imaging station 60. Also, it is particularly important to control the speed of blanket 44 under imaging station 60 to ensure proper jetting and deposition of ink droplets, thereby proper placement of the ink image on the surface of blanket 44 by imaging station 60.

[0061] In some embodiments, the substrate conveyor 80 is configured to move sheets 50 from an input stack 86 to an impression station 84 and additional stations of the system 10 described below, and then to an output stack 88 .

[0062] In some embodiments, the lower run of blanket 44 selectively interacts with an impression station 84 having an impression cylinder 82 to press an image pattern onto a target substrate compressed between blanket 44 and impression cylinder 82 under the action of pressure from pressure cylinder 90. For a single-sided printer (i.e., printing on one side of sheet 50), only one impression station 84 is required.

[0063] In some embodiments, system 10 includes an additional impression station, such as impression station 92, to enable duplex printing (i.e., printing on both sides of sheet 50). At impression station 92, blanket 44 passes between impression cylinder 98 and pressure cylinder 96, as also shown at impression station 84 and described above.

[0064] In the context of this disclosure and the claims, “duplex,” “two-sided,” and “duplex printing” are used interchangeably and refer to any suitable technique for printing or supporting the printing of images on both sides of a substrate, such as sheet 50.

[0065] In some embodiments, the substrate conveyor 80 is configured to move the sheet 50 to an impression station 84 that transfers a first ink image to a first surface of the sheet 50. The substrate conveyor 80 then further comprises a duplexing unit (not shown) configured to flip the sheet 50 between the two impression stations 84 and 92 and convey it to the impression station 92 for transferring a second ink image to a second surface of the sheet 50 opposite the first surface. This duplexing may be applied to all of the sheets 50.

[0066] Alternatively, duplex printing may be performed using any other suitable process sequence, such as, for example, mixed lots of simplex and duplex printing. For example, simplex and duplex printing may be alternated in a batch having any suitable predetermined number of sheets 50. That is, the substrate conveyor 80 is configured to move sheets 50 to and from the blanket 44 for transfer of the ink image (e.g., between impression stations 84 and 92) and then transport the printed sheets to the output stack 88.

[0067] In some embodiments, the configuration of system 10 also allows simplex printing to occur approximately twice as fast as it can print duplex printing.

[0068] In alternative embodiments, different configurations of substrate conveyor 80 may be used for printing onto continuous web substrates. Detailed descriptions and various configurations of sheet-fed simplex and duplex printing systems, and systems for printing onto continuous web substrates, are provided, for example, in U.S. Patent Nos. 9,914,316 and 9,186,884, PCT International Publication No. WO 2013 / 132424, U.S. Patent Publication No. 2015 / 0054865, and U.S. Provisional Patent Application No. 62 / 596,926, the disclosures of which are incorporated herein by reference in their entirety.

[0069] As briefly mentioned above, a sheet 50 or continuous web substrate (not shown) is transported by substrate conveyor 80 from an input stack 86 and passes through a nip (not shown) located between impression cylinder 82 and pressure cylinder 90 and / or between impression cylinder 98 and pressure cylinder 96. Within the nip, the surface of blanket 44 carrying the ink image is pressed firmly against sheet 50 (or other suitable substrate), for example by a compressible blanket (not shown) of pressure cylinder 90, such that the ink image is pressed against the surface of sheet 50 and cleanly separates from the surface of blanket 44. As mentioned above, after single-sided and / or double-sided printing, the sheet 50 is transported by substrate conveyor 80 to an output stack 88.

[0070] 1 , the chain delivery 85 extends between an input stack 86 and an output stack 88 through impression stations 84 and 92. In some embodiments, the substrate conveyor 80 further includes one or more grippers 87, each mounted along the chain delivery 85 and configured to grip and move a respective sheet 50 from the input stack 86 along the chain delivery 85. Each gripper 87 is configured to grip a sheet 50 at one or more edges and move a respective sheet 50 over flat and curved surfaces along the chain delivery 85.

[0071] In some embodiments, system 10 includes an image quality control station 55 that serves as a closed-loop inspection system integrated into system 10, also referred to herein as an automated quality control (AQM) system.

[0072] In some embodiments, station 55 may be located adjacent impression cylinder 82 as shown in FIG. 1, and / or at any other suitable location within system 10.

[0073] In other embodiments, system 10 may include additional image quality control stations 55 (not shown) located adjacent impression cylinder 98. Additional AQM systems may be used to inspect the ink images transferred to the second surface of sheet 50 at impression station 92. That is, system 10 may include one or more AQM systems, each of which may be used to inspect the ink images transferred to one or both sides of sheet 50 by impression stations 84 and 92, respectively.

[0074] In some embodiments, station 55 includes a camera (not shown) configured to capture one or more digital images of the above-mentioned ink images printed on sheet 50. In some embodiments, the camera may include any suitable image sensor, such as, for example, a contact image sensor (CIS), a complementary metal oxide semiconductor (CMOS) image sensor, and a scanner with a slit having a width of about one meter or any other suitable width.

[0075] In some embodiments, station 55 may include a spectrophotometer (not shown) configured to monitor the quality of the ink printed on sheet 50 .

[0076] In some embodiments, the digital images acquired by station 55 are transmitted to a processor, such as processor 20 or any other processor at station 55, configured to assess the quality of each printed image.

[0077] Based on the assessment and on the signals received from controller 54, processor 20 is configured to control the operation of the modules and stations of system 10. In the context of the present invention and in the claims, the term “processor” refers to any processing unit, such as processor 20 or any other processor connected to or integrated with station 55, configured to process signals received from the camera and / or spectrophotometer of station 55.

[0078] In some embodiments, the signal processing operations, control-related instructions, and other computational operations described herein may be performed by a single processor or shared among multiple processors of one or more computers.

[0079] In some embodiments, station 55 is configured to inspect the quality of the printed images and test patterns to monitor various attributes such as, but not limited to, image distortion, mechanical damage to the surface of the printed image, full image registration with sheet 50, color-to-color registration, print geometry, image uniformity, color profile and linearity, and print nozzle functionality.

[0080] In some embodiments, processor 20 is configured to automatically detect errors and defects, e.g., scratches or particles, that occurred during mechanical processing of sheet 50 based on images acquired by station 55. For example, one or more AQM stations may be positioned along the transport path of sheet 50 performed by substrate conveyor 80.

[0081] Additionally or alternatively, the processor 20 is configured to automatically detect geometric distortions or other errors in one or more of the above-mentioned attributes, for example, the processor 20 is configured to compare a design version of a given digital image with a digital image of a printed version of the given image captured by a camera.

[0082] In other embodiments, processor 20 may apply any suitable type of image processing software, for example to reference sheet 50 and / or test patterns, to detect distortions indicative of the errors described above. In some embodiments, processor 20 is configured to analyze the detected distortions to apply corrective action to a malfunctioning module and / or provide instructions to other modules or stations of system 10 to compensate for the detected distortions.

[0083] In some embodiments, by acquiring images of sheets 50, station 55 is configured to measure the various types of defects, distortions, and errors described above, as well as mechanical flaws and front-to-back registration errors that may occur in duplex printing. In some embodiments, processor 20 is configured to (i) sort sheets 50 having mechanical flaws or distortions that exceed a first set of predefined thresholds into a waste tray (shown below in FIG. 2A ), (ii) initiate corrective action for sheets 50 having mechanical flaws or distortions that exceed a second, lower set of predefined thresholds, and (iii) output sheets 50 having minor distortions, e.g., below the second set of thresholds, into output stack 88.

[0084] In some embodiments, processor 20 is configured to detect various types of defects based on the signals acquired by station 55: (i) defects in the substrate (e.g., blanket 44 and / or sheet 50), such as, for example, mechanical damage, small holes, and edge damage, and (ii) printing-related defects, such as, for example, irregular color spots, splatters, and stains.

[0085] In some embodiments, processor 20 is configured to detect these defects by comparing the printed portion to a respective reference portion of the original design, also referred to herein as a master. Processor 20 is further configured to classify the defects and, based on the classification and predefined criteria, discard sheets 50 having defects that are not within the specified predefined criteria.

[0086] In some embodiments, the processor of station 55 is configured to determine, for example, whether to stop operation of system 10 if the defect density exceeds a specified threshold. The processor of station 55 is further configured to initiate corrective actions in one or more of the modules and stations of system 10, as described above.

[0087] Corrective action may be taken on the fly (while system 10 continues the printing process) or offline by stopping printing operations and repairing the problem in the respective module and / or station of system 10. In other embodiments, any other processor or controller of system 10 (e.g., processor 20 or controller 54) is configured to initiate corrective action or stop operation of system 10 if the defect density exceeds a specified threshold.

[0088] Additionally or alternatively, processor 20 may be configured to receive signals, for example from station 55, indicative of additional types of defects and problems in the printing process of system 10. Based on these signals, processor 20 may be configured to automatically estimate a level of pattern placement accuracy and additional types of defects not described above.

[0089] In other embodiments, any other suitable method may be used to inspect the pattern printed on sheet 50 (or any other substrate mentioned above), for example using an external (e.g., offline) inspection system, or any other measurement fixture and / or scanner. In these embodiments, based on signals received from the external inspection system, processor 20 is configured to initiate any suitable corrective action and / or stop operation of system 10.

[0090] The configuration of system 10 is simplified and provided as an example only to clarify the present invention. The modules and stations and additional components and configurations described above in printing system 10 are described, for example, in U.S. Patent Nos. 9,327,496 and 9,186,884, PCT International Publication Nos. WO2013 / 132438, WO2013 / 132424, and WO2017 / 208152, U.S. Patent Application Publication Nos. 2015 / 0118503 and 2017 / 0008272, the disclosures of which are incorporated herein by reference in their entirety.

[0091] The particular configuration of system 10 is presented as an example to illustrate the particular problems addressed by embodiments of the present invention and to demonstrate the application of these embodiments in improving the performance of such systems, although embodiments of the present invention are in no way limited to this particular type of example system and the principles described herein may be applied to any other type of printing system as well. Substrate transport assembly with rolling balls to prevent scratches on print sheet - Patent 733636

[0092] Figure 2 is a schematic, pictorial diagram of a substrate transport assembly 100 mounted on a substrate conveyor 80, in accordance with an embodiment of the present invention. As described above in Figure 1, substrate conveyor 80 is configured to transport sheets 50 between an input stack 86 and an output stack 88 via impression stations 84 and 92, and optionally sort waste sheets 50 into a waste tray 99 of system 10. Sheets 50 may have ink images printed on one or both sides, as described in detail above in Figure 1.

[0093] In some embodiments, the substrate transport assembly 100 comprises one or more rotating element arrays, shown below in FIG. 2B, secured to respective plates, which are described in more detail below. The plates are attached to a chain delivery 85 at predetermined locations along the substrate conveyor 80. The rotating element arrays are configured to provide mechanical support to the sheet 50, such that one or more of the rotating elements are configured to rotate in response to physical contact with the sheet 50 as the gripper 87 moves the sheet 50 over the array, but the rotating elements do not move relative to the sheet 50 and have minimal friction with the sheet 50.

[0094] In some embodiments, the plates with fixed arrays of rotating elements are configured to match the shape of the respective locations and / or portions of the chain delivery 85 to which they are fixed. Additionally or alternatively, the plates with fixed arrays of rotating elements are configured to match the shape of the respective portions of the substrate conveyor 80.

[0095] In some embodiments, the rotating element includes an ink-repellent material, such as, for example, polytetrafluoroethylene (PTFE) or other suitable Teflon-based material, configured to prevent mechanical damage, such as scratches, on the printing surface of the sheet 50 opposite the rotating element.

[0096] In some embodiments, the array of rolling elements may comprise balls, rollers, bearings, any suitable combination thereof, or any other suitable type of rolling elements, as described in more detail below.

[0097] In the example of FIG. 2A, the substrate transport assembly 100 includes a number of perforated plates 111A-111G such that an array of rotating elements fits into the openings of each plate 111A-111G. In some embodiments, the perforated plates are coupled to a chain delivery 85 and are generally stationary. Thus, when the gripper 87 moves the sheet 50 over the plates 111A-111G, the sheet 50 hovers over the perforated plates and makes physical contact only with the surfaces of the rotating elements fixed within the plates 111A-111G and rotatable along the direction of movement of the sheet 50. However, the plate 111A is hidden in FIG. 2A because it is located below the drum adjacent to the impression station 92, but is shown in more detail later in FIG. 2B.

[0098] In some embodiments, perforated plate 111C is located between the path of sheets 50 and waste tray 99. If the printing process does not involve sheet disposal, plate 111C is maintained between the path of sheets 50 and waste tray 99. If the printing process involves sheet disposal, plate 111C may be removed from the configuration of system 10.

[0099] In an alternative embodiment, the perforated plate 111C is configured to move to sort the waste sheets 50 into the waste tray 99.

[0100] In some embodiments, plate 111G is mounted adjacent output stack 88 to prevent scratches on print sheet 50.

[0101] In embodiments, sheet 50 may have a typical length of 520 mm to 1050 mm and a typical width of 360 mm to 750 mm, although in other embodiments system 10 may print ink images on sheets having any other suitable length and width. System 10 is also configured to print ink images on substrates having any other shape and size. In some embodiments, plate 111B is configured to move (e.g., a few mm) along the X-axis to block the gap between plates 111B and 111C that could result in loss of short sheets that may fall between plates 111B and 111C.

[0102] 2B is a schematic pictorial diagram of plates 111A-111F of a substrate transport assembly 100, according to an embodiment of the present invention. In some embodiments, the substrate transport assembly 100 comprises flat plates, such as plates 111B, 111C, 111D (and plate 111G shown in FIG. 2A above), and curved plates, such as plates 111E, 111F, and 111F.

[0103] In some embodiments, the plates 111A-111G may comprise any suitable material, such as, for example, an aluminum alloy (e.g., H32 5052), and may have any suitable dimensions. For example, a thickness of about 2 mm allows the plates to be shaped to any suitable radius of curvature, while still maintaining plate durability such that the preformed curved shape is not distorted over time by large volumes (e.g., millions) of sheets 50 transported by the substrate conveyor 80.

[0104] In some embodiments, the plates 111A-111G may have any suitable width and length, such as a width of about 50 cm, similar to the width of the chain delivery 85, and a typical length of about 1 meter, although the above dimensions are provided as examples and the actual dimensions of each plate 111A-111G are designed to cover an area along the substrate conveyor 80 that may result in mechanical damage (e.g., scratches) to the surface of the sheet 50 facing the plate.

[0105] In some embodiments, each of the perforated plates 111A-111G has a number of rotating elements 110 assembled into respective openings in the plate. The assembly of the rotating elements 110 may be done by mounting each element 110 on a shaft, or in a ball array, in a process sequence shown below in FIG. 3, or using any other suitable technique. For example, each of the plates 111A-111G may have an array of PTFE balls having a diameter of about 10 mm, each ball fitting into a respective 11 mm square opening in the perforated plate. The ball array may have any suitable pitch size, such as, for example, 50 mm.

[0106] In other embodiments, the rotating elements may comprise rollers having any suitable diameter, for example about 10 mm, and any suitable width, for example about 15 mm. In these embodiments, the plate may have a rectangular opening of about 11 mm in the X-axis direction and 16 mm in the Y-axis direction, with the rollers fitting into the openings such that each roller rotates generally in the Y-axis direction to move the sheet 50 along the X-axis.

[0107] The configurations of apertures and rotating elements described above are provided as examples for conceptual clarity, and in other embodiments, each of the plates 111A-111G may have any other suitable configuration having any suitable type or types of rotating elements arranged in one or more arrays having any suitable dimensions.

[0108] In some embodiments, the surfaces of the rotating elements 110 (e.g., balls) that make physical contact with the balls are fitted along a curved surface that is parallel to the curved surface of the respective curved plate. That is, the respective axially mounted plates and / or balls are shaped to match any desired radius of curvature or other shape of the surface they are designed to support. Also, in such embodiments, one or more arrays of rotating elements 110 are configured to match any shape of the substrate conveyor 80 or any other substrate conveyor.

[0109] In some embodiments, gripper 87 is configured to move sheet 50 along a curved surface such that the balls of the array are arranged to provide mechanical support to sheet 50 along the curved surface without sufficient friction that could scratch the surface of sheet 50.

[0110] In some embodiments, the plates of the substrate transport assembly 100 may be integrated into the configuration of the system 10, for example, during manufacture and installation of the system 10 at a printing facility. Additionally or alternatively, at least one of the plates 111A-111G, or the entire substrate transport assembly 100, may be installed after assembly and installation of the system 10 as an upgrade kit, also referred to herein as an add-on kit, to eliminate, or at least substantially reduce, mechanical damage on surfaces of the sheets 50 that come into physical contact with components of the substrate conveyor 80.

[0111] In the example configuration of Figure 2B, the curved plates have a concave shape. In other embodiments, at least one of the plates may have any suitable shape, such as, but not limited to, a concave shape, a convex shape, and combinations thereof.

[0112] In some embodiments, at least one of the plates may comprise an assembly of multiple plates coupled together. For example, plate 111F may comprise a flat plate 112 and two curved plates 113 and 114 having different radii of curvature.

[0113] This particular configuration of plates 111A-111G is shown by way of example to illustrate the particular problems addressed by embodiments of the present invention, such as marring an image printed on sheet 50, and to demonstrate the application of these embodiments in improving the performance of system 10. However, embodiments of the present invention are in no way limited to this particular type of example system, and the plates and arrays of rotating elements and principles described herein may likewise be applied to other types of printing systems and other configurations of rotating elements configured to prevent mechanical damage to the surface of sheet 50 of any other type of target substrate. Ball assembly in arrays of rolling elements

[0114] 3 is a schematic diagram illustrating a process sequence for assembling a rotating ball 200 into an array of rotating elements, according to an embodiment of the present invention. In some embodiments, the ball 200 is made of or coated with PTFE or other suitable material, such as, but not limited to, other Teflon-based materials, and may replace any of the rotating elements 110 shown in FIG. 2B above.

[0115] The assembly process begins in step 1 by manufacturing the shaft 202 and threading it into a pre-formed channel 210 along the diameter of the ball 200. In some embodiments, the shaft 202 comprises a wire of any suitable material, such as, for example, a suitable stainless steel alloy, having a typical diameter of about 1 mm and a typical width of about 30 mm.

[0116] In some embodiments, the shaft 202 may be threaded into a channel 210 along the Y axis and then bent to form two horizontal portions 204 and 208 along the Y axis, a vertical portion 206 along the Z axis, and two knees 205 and 207 joining the vertical and horizontal portions. At least one of the threading and bending processes may be performed using a suitable manufacturing machine.

[0117] In an embodiment, the channel 210 and the axle 202 are sized and shaped to fit together to prevent any lateral movement of the portion 204 in the X and Z axes of the channel 210 while allowing the axle 202 to easily pass through the channel 210. Additionally, the ball 200 and the axle 202 are made of suitable materials selected to minimize friction between them as the portion 204 rotates about the Y axis within the channel 210.

[0118] Reference is now made to step 2, which is a top view of ball 200 and shaft 202 in the XY plane. In step 2, ball 200 and shaft 202 are fitted into respective preformed openings 220 and 222 in plate 211, which may correspond to and replace any of plates 111A-111G described above in FIG. 2B. In the example of FIG. 3, openings 220 have an 11 mm square shape as described above, and each of openings 222 comprises three connected slots 224, 226, and 230.

[0119] In some embodiments, portions 206-208 of shaft 202 are inserted into slots 224 of opening 222 at an insertion angle 214 relative to the X-axis. However, portion 204 of shaft 202 is located above top surface 228 of plate 211 to position a surface of ball 200 above surface 228 of plate 211. That is, the top surface of ball 200 protrudes beyond top surface 228 of plate 211 to mechanically support seat 50 and prevent physical contact between seat 50 and any surface of plate 211.

[0120] In the context of the present invention and the claims, slot 224 is also referred to herein as an insertion slot, slot 226 is also referred to herein as a rotation slot, and slot 230 is also referred to herein as a locking slot.

[0121] In some embodiments, after inserting portions 206-208 of shaft 202 into slot 224, ball 200 and shaft 202 rotate clockwise in the XY plane as indicated by axis 212. This rotational action may be performed manually or with a suitable rotation device, and the direction of rotation (e.g., clockwise or counterclockwise) depends on the configuration and shape of opening 222.

[0122] In some embodiments, during rotation, portion 204 is positioned above top surface 228 as described above, portion 206 rotates clockwise through slot 226, and portion 208 rotates below the bottom surface (not shown) of plate 211.

[0123] Reference is now made to step 3, which is a top view of ball 200 and plate 211 in the XY plane. In step 3, shaft 202 completes rotation through slot 226 at locking angle 216 and is locked in the locked position by slot 230. In the example of FIG. 3, locking angle 216 extends between the X-axis and an extension of shaft 202. However, in the locked position, shaft 202 is parallel to and configured to rotate about the Y-axis. That is, shaft 202 is perpendicular to the X-axis, which is the direction of movement of seat 50 as described above.

[0124] In some embodiments, in the locked position, ball 200 is configured to rotate about the Y axis such that the surface of ball 200 moves along the X axis in response to physical contact with sheet 50 being moved by gripper 87 along the X axis, as described above in FIG. 2A.

[0125] As described above in steps 2 and 3, slots 224 , 226 , and 230 of plate 211 are configured to receive shaft 202 at insertion angle 214 and lock shaft 202 at locking angle 216 that is different from insertion angle 214 .

[0126] This particular configuration of axis 202 and slots 224, 226, and 230 is shown by way of example to illustrate particular problems associated with positioning and fixing ball 200 or any other suitable rotating element in any suitable array or plate that are addressed by embodiments of the present invention and to demonstrate the application of these embodiments in improving the performance of system 10. However, embodiments of the present invention are in no way limited to this particular type of positioning and fixing device, and the principles described herein may be applied to other configurations for positioning and fixing rotating elements in plates or other types of arrays as well. Technique for locking Y-axis and Z-axis ball movement at locking position

[0127] FIG. 4A is a schematic cross-sectional view of ball 200 and shaft 202 fixed to plate 211 along the Y and Z axes, according to an embodiment of the present invention.

[0128] As described above, in step 3 of FIG. 3, shaft 202 is engaged by slot 230 such that ball 200 is configured to rotate in the Y-axis direction in response to physical contact with surface 253 of sheet 50 being moved in the X-axis direction by gripper 87.

[0129] In some embodiments, portion 204 of shaft 202 is configured to be mounted above surface 228 of plate 211 such that a surface of ball 200 provides mechanical support to seat 50 at a distance 250 from surface 228, allowing rotation of ball 200 about the Y axis. In the example configuration of FIG. 4A , distance 250 is large enough (e.g., about 5.5 mm) to prevent surface 253 of seat 50 from making physical contact with surface 228, and to prevent physical contact between two adjacent balls 200 or at the edge of plate 211.

[0130] In some embodiments, an imaginary plane, also referred to herein as surface 255, that is generally parallel to surface 253 of sheet 50 is formed by an imaginary web of straight lines connecting between the upper plats of surfaces 236 of all balls attached to substrate 211. In some embodiments, sheet 50 is moved along surface 255 at a distance of about 5.5 mm from surface 228 of plate 211.

[0131] As described above in FIG. 2B, system 10 may include one or more curved plates, such as plate 111A, having an array of rolling elements, such as balls 200, fixed along the curved surface of the plate.

[0132] In some embodiments, surface 228 of plate 211 may have a curved shape such that ball 200 mated to surface 228 is configured to form a curved surface 255. In these embodiments, gripper 87 of system 10 is configured to move sheet 50 along curved surface 255 such that sheet 50 hovers over surface 228 without making physical contact with surface 228.

[0133] In some embodiments, opening 222 is configured to lock shaft 202 against movement along the Y axis by slot 226 surrounding portion 206. Also, shaft 202 cannot move in the Z axis direction because portions 204 and 208 are above and below surfaces 228 and 238, respectively, of plate 211. Allowing rotation of the ball around the Y axis in the locked position

[0134] 4B is a schematic side view of ball 200 and axle 202 secured to plate 211, according to an embodiment of the invention. As described above, gripper 87 of system 10 moves sheet 50 in a direction 260 parallel to the X-axis, bringing it into physical contact with surface 236 of ball 200.

[0135] In some embodiments, ball 200 is configured to rotate about portion 204 oriented parallel to the Y-axis. The rotation of the ball is caused by physical contact between the ball surface and sheet 50, as indicated by arrow 270. However, since the kinetic energy of moving ball 200 is received solely from sheet 50, the ball remains stationary when sheet 50 is at rest on surface 236. That is, ball 200, which is at least partially made of PTFE, is passive and rotates only due to the motion of sheet 50. Thus, ball 200 is configured to mechanically support sheet 50 without damaging the ink image generated by system 10 on surface 253 of sheet 50.

[0136] In some embodiments, in the locked position, ball 200 will not rotate in response to any undesired movement of seat 50 along the Y and / or Z axes, and thus ball 200 may provide mechanical support to seat 50 and resist movement of seat 50 in any direction other than parallel to the X axis. An array of rotating elements mounted on a frame

[0137] 5 is a schematic pictorial diagram of ball 200 mounted on frame 300 according to another embodiment of the present invention. Frame 300 can replace at least one of plates 111B, 111C, and 111D shown in Figures 2A and 2B above.

[0138] In some embodiments, the frame 300 comprises a bar 304 that lies along the Y-axis with multiple arms 302 coupled to it and extending from the bar 304 in the X-axis direction.

[0139] In some embodiments, each of the arms 302 has multiple apertures 220 and 222 drilled at a predetermined distance 306 from each other. As described in FIG. 3, the apertures 220 and 222 can be used to secure the balls 200 during manufacturing and / or field installation of the frame 300 in the system 10. As further described in FIG. 3 above, each ball 200 has an individual axis 202, which is aligned along at least one of the X-axis and the Y-axis, as shown in FIG. 5. Also, at least two, and typically all, of the axes 202 in the array of perforated plates in FIG. 2B above and the array of frames 300 in FIG. 5 are positioned parallel to each other in the Y-axis direction, which is orthogonal to the direction of movement of the sheet 50 along the X-axis.

[0140] In some embodiments, the distance between the arms 302 and the location of the openings 220 and 222 in the arms determine the distance 308 between the balls 200 secured to adjacent arms 302. In the example of FIG. 5, distance 308 appears to be greater than distance 306, but in other embodiments, the balls 200 may be arranged in any other configuration to set similar or different distances between the balls 200 along the X and Y axes.

[0141] In alternative embodiments, at least some of the balls 200 may be replaced with any other suitable type of rolling elements, such as, but not limited to, rollers and / or bearings. In these embodiments, the frame 300 may include one or more types of rolling elements arranged in any suitable configuration.

[0142] The configuration of frame 300 is provided by way of example and is simplified for conceptual clarity. In other embodiments, frame 300 may comprise an array of axes arranged in any suitable configuration. For example, rods with embedded rotating elements may be arranged in a cross configuration along any suitable axis, such as, for example, the X-axis and the Y-axis. In this configuration, the use of plates, for example, as described above in FIG. 2B, and the bars and arms described in FIG. 5 may be omitted. Additionally or alternatively, in the array of balls, at least one row of balls may be replaced with an array of cylinders or any other suitable type of rotating elements.

[0143] In other embodiments, a single axis may be shared by two or more rotating elements (e.g., balls, cylinders, or a combination thereof). Upon physical contact with sheet 50, one or more of the rotating elements described above may rotate about the Y axis, thereby enabling movement of sheet 50 along the X axis with minimal friction, as described above.

[0144] In some embodiments, the disclosed techniques may be used to couple any print substrate, such as sheet 50, to any substrate conveyor at any suitable location along the path of a printing system. For example, a perforated plate having a structure similar to perforated plate 111E may be used to clamp sheet 50 to impression cylinder 82 to improve the image acquisition process by image quality control station 55. Additionally or alternatively, a perforated plate having the rotating elements described above may be used at any suitable location along substrate transport assembly 100 to prevent unwanted friction and damage to ink images printed on the surface of sheet 50 facing substrate transport assembly 100.

[0145] In some embodiments, the techniques disclosed in this invention may be used, mutatis mutandis, to prevent surface damage to any object being transported by a conveying system on any surface.

[0146] The configuration of the substrate transport assembly 100 is provided as an example to demonstrate an example printing system in which the substrate transport assembly 100 may be integrated and used. Additionally or alternatively, any other suitable configuration may be used in any other type of system for transporting a substrate. For example, (a) the substrate transport assembly 100 may be implemented in a system for directly printing (e.g., ink jetting onto sheet and / or continuous web substrates) onto both sides of a target substrate, and (b) substrate transport assemblies of different configurations may include a rotating surface that is not limited to multiple rotating elements. For example, a single-piece body (or a multi-piece body) provides the same functionality to the system 10 (or any other system) as the rotating elements (e.g., rotating element 110 and / or ball 200).

[0147] In some embodiments, for the direct printing system of example "(a)" described in the previous paragraph, the system may include an imaging station configured to apply one or more droplets of printing fluid (e.g., ink) to a target substrate to form an image. Such a system may not have a blanket or any other type of ITM, and the substrate conveyor may have the same configuration and / or functionality as the substrate transport assembly 100 described above, or any other suitable configuration.

[0148] Although the embodiments described herein primarily address digital printing systems, the methods and systems described herein may be used in other applications, such as any type of printing system (as described above) or any other type of system configured to transport one or more substrates without damaging the surface. It is therefore understood that the above-described embodiments are cited as examples, and that the present invention is not limited to what has been specifically shown and described above. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described above, as well as variations and modifications thereof that would occur to a person skilled in the art upon reading the above description and that are not disclosed in the prior art. Documents incorporated by reference into this patent application shall be considered as integral parts of this application, with the exception that if any term is defined in these incorporated documents in a manner that contradicts the definition expressly or impliedly made herein, then only the definition in this specification shall be considered.

Claims

1. 1. A system comprising: an imaging station configured to apply droplets of one or more printing fluids to a target substrate to form an image on the target substrate; a substrate conveyor comprising one or more perforated plates having a plurality of openings and configured to grip and move the target substrate to and from the imaging station for forming the image, the substrate conveyor comprising one or more rotating elements, the one or more rotating elements being fitted into respective openings of the one or more perforated plates and configured to provide mechanical support to the target substrate, at least one of the one or more rotating elements being configured to rotate in response to physical contact with the target substrate by receiving kinetic energy from the target substrate as the target substrate moves over the one or more rotating elements, at least one of the one or more perforated plates comprising: (i) a bar positioned along a first axis; and (ii) at least a first arm and a second arm, the first arm and the second arm coupled to the bar and extending from the bar along a second axis, the second axis being different from the first axis; A system comprising:

2. The system of claim 1 , wherein the one or more perforated plates comprise a first perforated plate that is flat and a second perforated plate that is curved.

3. The system of claim 1 , wherein the first axis or the second axis is parallel to a direction of movement of the target substrate.

4. 2. The system of claim 1, wherein the first arm and the second arm are positioned (i) parallel to one another along the second axis, and (ii) a first distance from one another along the first axis.

5. 5. The system of claim 4, wherein the plurality of openings are arranged in at least one of the first arm and the second arm along the second axis at a second distance from each other, and the one or more rotating elements are fitted into openings that are at the second distance from each other.

6. The system of claim 5 , wherein the first distance is different from the second distance.

7. 7. The system of claim 1, wherein the one or more rotating elements are attached to a wire and at least one of the one or more perforated plates comprises one or more slots configured to receive the wire at a first angle and lock the wire at a second angle, the second angle being different from the first angle.

8. The system of any one of claims 1 to 7, wherein at least one of the one or more rolling elements comprises a ball.

9. The system of any one of claims 1 to 7, wherein at least one of the one or more rolling elements comprises at least a roller or a bearing.

10. 1. A method comprising: providing a plurality of rotating elements for mechanically supporting a target substrate, at least one of the plurality of rotating elements rotating in response to physical contact with the target substrate by receiving kinetic energy from the target substrate as the target substrate moves over the plurality of rotating elements; Fixing the plurality of rotating elements to a plurality of respective locations on a mounting element; assembling the attachment element to a substrate conveyor of a digital printing system, the assembling comprising assembling a frame, the frame being perforated and having (i) a bar located along a first axis, and (ii) at least a first arm and a second arm coupled to the bar and extending from the bar along a second axis, the second axis being different from the first axis; A method comprising:

11. The method of claim 10 , wherein assembling the mounting element comprises assembling the mounting element to the substrate conveyor during manufacture of the digital printing system.

12. The method of claim 10 , wherein assembling the mounting element comprises assembling the mounting element to the substrate conveyor after completing manufacturing of the digital printing system.

13. The method of claim 12 , wherein assembling the mounting element comprises assembling the mounting element to the substrate conveyor after the digital printing system is installed at a printing facility.

14. The method of claim 10 , wherein assembling the mounting element comprises assembling (i) the bar, or (ii) first and second arms parallel to a direction of movement of the target substrate.

15. 11. The method of claim 10, wherein the first arm and the second arm are (i) positioned parallel to one another along the second axis and (ii) positioned a first distance from one another along the first axis, and at least a first position and a second position among a plurality of respective positions of the mounting element are positioned a second distance from one another, and fixing the plurality of rotating elements comprises positioning a first rotating element and a second rotating element among the plurality of rotating elements at the second distance from one another.

16. The method of claim 15 , wherein the first distance is different from the second distance.

17. The method of any one of claims 10 to 16, wherein fixing the plurality of rolling elements comprises fixing at least a ball.

18. 18. The method of any one of claims 10 to 17, wherein the substrate conveyor comprises one or more perforated plates having a plurality of openings, at least one of the one or more perforated plates comprising at least a slot, the method comprising attaching at least one of the plurality of rotating elements to a wire, and fixing the plurality of rotating elements comprises positioning the wire within the slot at a first angle and locking the wire to at least one of the one or more perforated plates at a second angle, the second angle being different from the first angle.

Images