Flattener Nip Control for Duplex Ink Adhesion

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Solution Overview

Problem

Ink adhesion issues on the second side of media sheets occur due to oil contamination from the flattener roll in duplex printing operations, leading to productivity losses when trying to prevent oil transfer between sheets, especially in high-speed printing devices.

Innovation Solution

A printing apparatus with a controller that reduces the inter-copy gap distance between media sheets to prevent contact between rotational flattener members, minimizing release agent transfer and maintaining the flattener nip closed, thereby ensuring consistent ink adhesion on both sides of the media sheets without productivity loss.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If the flattener nip is opened and closed between sheets during duplex jobs to prevent oil transfer, then ink adhesion on the second side is improved, but productivity is reduced

Engineering Contradiction:

Improveink adhesionVSAvoidduplex printing speed

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The harmful oil film is selectively removed from the pressure roll surface using a cleaning mechanism, allowing the flattener nip to remain continuously closed while preventing oil contamination of the media sheet backside

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

A release agent distributer applies a controlled release agent to the pressure roll surface, creating a barrier that prevents oil transfer to media sheets while maintaining proper flattening function

Inventive Principle:

Principle #24Intermediary (Mediator)

2Object-affected harmful factors

If the inter-copy gap distance is reduced to prevent flattener roll contact, then oil contamination is prevented, but media transport flexibility is reduced

Engineering Contradiction:

Improveoil contaminationVSAvoidmedia transport flexibility

Core Design Contradiction:

Object-affected harmful factorsVSAdaptability or versatility

Solution Approach 1:

The mechanical solution of varying inter-copy gap distance is replaced with a chemical/cleaning solution that actively manages oil film presence on the pressure roll, allowing consistent media transport without contamination

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If the flattener nip remains closed during inter-copy gaps to maintain productivity, then oil transfer occurs to the pressure roll, but ink adhesion is compromised

Engineering Contradiction:

Improvecontinuous operationVSAvoidink adhesion

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The cleaning mechanism proactively removes oil from the pressure roll surface before it can contaminate media sheets, and the release agent is applied in advance to prevent oil transfer during subsequent printing operations

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The oil film that naturally forms on the pressure roll during continuous operation is converted from a harmful contaminant into a controlled element through the release agent system, which manages its presence to prevent media sheet contamination while maintaining flattener function

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution maintains ink adhesion on both sides of media sheets during duplex printing, enhancing productivity by preventing oil contamination and allowing continuous operation without the need for frequent nip opening and closing, thus improving overall printing efficiency.

Implementation Method 1

a release agent distributer configured to distribute release agent on the first rotational flattener member

Methodology Applied

Scientific EffectSurface coating: Deposition (physical)

Implementation Method 2

The flattener can include a first rotational flattener member including a first rotational flattener member surface and a second rotational flattener member coupled to the first rotational flattener member at a flattener nip. The flattener nip can be configured to flatten the ink jet drops of an image on a media sheet in the flattener nip

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentUS8511816B2Apparatus and method for operating a flattener in an ink-based printing apparatus

Publication Date: 2013.08.20 XEROX CORP

AI summary

An apparatus and method that operates a flattener in an ink-based printing apparatus. The printing apparatus can include a media path configured to transport media sheets. The printing apparatus can include a marking module configured to jet ink drops to generate images on the media sheets. The printing apparatus can include a flattener configured to flatten the ink jet drops of the images on the media sheets in a flattener nip. The printing apparatus can include a release agent distributer configured to distribute release agent on a first rotational flattener member. The printing apparatus can include a controller configured to control the printing apparatus to reduce an inter-copy gap distance between a first media sheet and a second media sheet to prevent a first rotational flattener member from contacting a second rotational flattener member between the first media sheet and the second media sheet.