Kit for creating flat simulated color photographic prints using xerography

A kit is provided for creating simulated photographic prints using xerographic imaging. The kit comprises a transparent carrier suitable for having a reverse reading toner image fused thereto and a reflective backing sheet, the latter of which is coated with a heat activatable adhesive material for bonding the latter to the former. The kit further includes a rigid surface of tempered glass upon which the transparent substrate is supported during bonding. An adhesive member is provided for covering the transparent carrier during the process of making prints.

BACKGROUND OF THE INVENTION
 This invention relates generally to a method and apparatus for producing
 continuous tone images with near photographic print qualities using
 xerography.
 In the practice of conventional xerography, it is the general procedure to
 form electrostatic latent images on a xerographic surface by first
 uniformly charging a charge retentive surface such as a photoreceptor. The
 charged area is selectively dissipated in accordance with a pattern of
 activating radiation corresponding to original images. The selective
 dissipation of the charge leaves a latent charge pattern on the imaging
 surface corresponding to the areas not exposed by radiation.
 This charge pattern is made visible by developing it with toner by passing
 the photoreceptor past one or more developer housings. In monochromatic
 imaging, the toner is generally comprises black thermoplastic powder
 particles which adhere to the charge pattern by electrostatic attraction.
 The developed image is then fixed to the imaging surface or is transferred
 to a receiving substrate such as plain paper to which it is fixed by
 suitable fusing techniques.
 Recently, there has been a great deal of effort directed to the development
 of color copiers/printers which utilize the xerographic process. Such
 efforts have resulted in the recent introduction of the Xerox.TM. 5775.TM.
 copier/printer and the Fuji XeroxA-Color 635 machine.
 The quality of color xerographic images on paper has approached the quality
 of color photographic prints. However, color xerographic prints fall short
 because they do not have the uniform gloss, dynamic range or brilliance
 typical of photographic prints. Nor do xerographic prints have the feel of
 photographic prints because the paper usually used is too lightweight and
 too limp.
 Typically the surface of color toner images is irregular, therefore, rather
 rough or lumpy. The behavior of incident white light vis-a-vis such color
 images is believed to be as follows:
 Some of the white light incident on the substrate carrying the color toner
 images specularly reflects off the substrate.
 Some of the light goes down into the paper, scatters around and comes back
 out in various directions, some through the toner and some not.
 Because the toner surface is rough or irregular some of the light incident
 thereon is reflected off the toner in various directions.
 Some of the light incident on the irregular toner surfaces passes through
 the toner into the paper and comes back out in various directions.
 White light becomes colored due to selective absorption as it passes
 through toner. The light then goes down into the paper and back out
 through the toner whereby it becomes more colored through more absorption.
 As will be appreciated, any white light which does not pass through the
 toner diminishes the appearance of the final print.
 Attempts to make up this deficiency in conventionally formed color toner
 images have led to the lamination of xerographic images on paper using a
 transparent substrate. This procedure has been only partially successful
 because the lamination process tends to reduce the density range of the
 print resulting in a print that has less shadow detail. The lamination
 process also adds significant weight and thickness to the print.
 Additionally, it is believed that the aforementioned lamination process
 does not produce good results because typically the color toner images at
 the interface between the laminate and the toner do not make suitable
 optical contact. That is to say, the initially irregular toner image at
 the interface, is still irregular (i.e. contains voids) enough after
 lamination that light is reflected from at least some of those surfaces
 and is precluded from passing through the toner. In other words, when
 there are voids between the transparency and toner image, light gets
 scattered and reflected back without passing through the colored toner.
 Loss of image contrast results when any white light is scattered, either
 from the bottom surface of the transparent substrate or from the irregular
 toner surfaces and doesn't pass through the toner.
 A known method of improving the gloss of color xerographic images on a
 transparent substrate comprises refusing the color images. Such a process
 was observed at a NOMDA trade show in 1985 at a Panasonic exhibit. The
 process exhibited was carried out using an off-line transparency fuser,
 available from Panasonic as model FA-F100, in connection with a color
 printer which was utilized for creating multi-color toner images on a
 transparent substrate for the purpose of producing colored slides. Since
 the finished image from the color printer was not really suitable for
 projection, it was refused using the aforementioned off-line refuser. To
 implement the process, the transparency is placed in a holder intermediate
 a clear relatively thin sheet of plastic and a more sturdy support. The
 holder is used for transporting the imaged transparency through the
 off-line refuser. After passing out of the refuser, the transparency is
 removed from the holder. This process resulted in an attractive high gloss
 image useful in image projectors. The refuser was also used during the
 exhibit for refusing color images on paper. However, the gloss is
 image-dependent. Thus, the gloss is high in areas of high toner density
 because the toner refuses in contact with the clear plastic sheet and
 becomes very smooth. In areas where there is little or no toner the gloss
 is only that of the substrate.
 The following is a discussion of prior art which may be relevant to the
 patentability of the present invention:
 U.S. Pat. Nos. 4,686,163 and 4,600,669 describe an electrophotographic
 imaging method that uses an element comprising a photoconductive layer on
 an electrically conducting substrate capable of transmitting actinic
 radiation to which the photoconductive layer is responsive, and a
 dielectric support, releasably adhered to the substrate, comprising the
 photoconductive layer or an overcoat thereof forming a surface of the
 element capable of holding an applied electrostatic charge. To use the
 element, the surface of the dielectric support is charged, and the
 photoconductive layer is imagewise-exposed to actinic radiation, thereby
 forming a developable electrostatic image on the dielectric surface. The
 electrostatic image, in turn, is developed with toner to form a first
 color image. A composite color image is formed on the element by repeating
 the sequence one or more times with imagewise exposure of the
 photoconductive layer to actinic radiation transmitted through the
 substrate, and developing over each preceding image with a different color
 toner. The composite toner image is transferred with the dielectric
 support to a receiving element to form a color copy such as a three-color
 filter array or a color proof closely simulating the color print expected
 from a full press run.
 The dielectric support on the photoconductive layer comprised a transparent
 blend of poly(vinylacetate-co-crotonic acid, 95/5 mole ratio) and
 cellulose acetate butyrate. The resulting multicolor proof presented a
 multicolor toner image against a white paper background and protected by
 the overlying dielectric support, thus accurately resembling a multicolor
 print from a full press run.
 The receiver element to which the dielectric support and composite toner
 image are transferred can be any suitable material against or through
 which the toner image is desired to be viewed. The receiver can be print
 stock, such as paper, upon which a press run will be conducted. The
 receiver can also be of transparent material such as a polymeric film.
 With respect to the latter, the invention also contemplates, as an
 embodiment, transfer of the composite toner image and dielectric support
 to image-bearing elements such as microfilm or microfiche so that the
 composite color image forms information in addition to image information
 already present on such image-bearing elements. In addition, the invention
 contemplates the use of transparent glass or nonbirefringent translucent
 polymeric materials such as cellulose esters for use as the receiver.
 Receivers manufactured from such materials are suited for use in forming
 three-color filter arrays by the process described herein involving the
 formation of filter array matrices of the complementary colorants cyan,
 magenta and yellow in the respective color toner imaging steps. If
 desirable, the receiver can also contain a suitable overcoat layer adapted
 to soften under the influence of pressure and heat during the transfer
 step. In this manner, the adhesion of the dielectric support and composite
 toner image to the receiver can be enhanced.
 The electrophotographic element bearing the multicolor toner image is moved
 to a separate lamination device comprising heated metal and rubber rolls,
 together forming a nip. The toner image is passed through the nip with and
 against a white receiver paper at a roll temperature of 100.degree. C.
 (212.degree. F.) and a pressure of 225 pounds per square inch (1.551 MPa)
 to effect transfer of the dielectric support and composite image to the
 receiver followed by peeling off the rest of the electrophotographic
 element.
 U.S. Pat. No. 4,066,802 granted on Jan. 3, 1978 to Carl F. Clemens
 discloses a method of decalcomania in which a toner image pattern is
 formed on a transfer member which has been overcoated with an adhesive
 material. A polymeric sheet is interposed between the toner image and a
 cloth or other image receiving medium. The polymeric sheet assists in the
 permanent adherence of the toner imaging pattern to the cloth material or
 other medium when the composite is subjected to heat and pressure. The
 transfer member and method of its use are set forth. Another embodiment
 discloses the use of solvent to fix the image to a cloth material.
 U.S. Pat. No. 5,065,183 granted on Nov. 12, 1991 to Morofuji et al
 discloses a multicolor printing method for printing multicolor picture
 images upon a material or object to be printed comprises the steps of, in
 accordance with a first embodiment of the invention, the formation of a
 multicolor toner image upon a flexible belt by means of
 electrophotographic printing methods or techniques, and the transfer of
 such multicolor toner image directly to the material or object to be
 printed, such as, for example, a container made of, for example, metal,
 paper, plastic, glass, or the like, by means of a thermo-transferring
 process. In accordance with a second embodiment of the invention, the
 multicolor toner image is formed upon a plastic film, which is laminated
 upon the flexible belt, by means of electrophotographic printing methods
 or techniques, and the plastic film is then transferred to and fused upon
 the container. In accordance with a third embodiment of the invention, a
 photoconductive member is irradiated by means of exposure light upon a
 rear surface thereof wherein the multicolor picture images are also formed
 by electrophotographic printing methods or techniques. In this manner,
 previously formed toner images upon the photoconductive member do not
 interfere with the image exposure processing.
 U.S. Pat. No. 5,126,797 granted on Jun. 30, 1992 to Forest et al discloses
 a method and apparatus for laminating toner images wherein a toner image
 on a receiving sheet is laminated using a transparent laminating sheet fed
 from the normal copy sheet supply of a copier, printer or the like. The
 laminating sheet is fed into laminating contact with the toner image after
 the toner image has been formed on a receiving sheet. The resulting
 sandwich is fed through the fuser laminating the image between the sheets.
 The invention is particularly usable in forming color transparencies.
 U.S. Pat. No. 5,108,865 granted to Zwaldo et al on Apr. 28, 1992 discloses
 a method including the steps of:
 contacting an image (preferably multi-toned image) with a transfer web
 (intermediate receptor layer) comprising in sequence, a carrier layer, a
 transferable release layer, and a releasable adhesive layer (releasable
 from the carrier layer along with the transferable release layer so that
 both layers transfer at once), said adhesive layer being in contact with
 said toned image, said contacting being done under sufficient heat and/or
 pressure to enable said toned image to be adhered to said releasable
 adhesive layer with greater strength than the adherence of said toned
 image to said imaging surface of said photoconductive layer;
 separating the transfer web and said photoconductive layer so that the
 toned image is removed from said photoconductive layer and remains adhered
 to the adhesive layer of the transfer web;
 contacting the surface of the transfer web having both the multi-toned
 image and adhesive thereon with a permanent receptor surface;
 adhering the adhesive on the transfer web to the permanent surface; and
 removing the carrier layer of the transfer web from the adhesive and the
 release layer of the transfer web so that an image article is formed of
 the permanent receptor, multi-toned image, releasable adhesive, and the
 resultant surface coating of the release layer which is furthest away from
 the permanent receptor.
 U.S. Pat. No. 4,949,103 granted to Schmidlin et al on Aug. 14, 1990
 discloses a direct electrostatic printing (DEP) device utilized for
 printing mirror or reverse/wrong reading toner images on a transparent
 substrate. An adhesive coating on the transparent substrate on the toner
 image side thereof enables the transparent substrate to be affixed to a
 substrate such as an envelope such that the mirror images are right
 reading.
 U.S. Pat. Nos. 4,868,049 and 4,724,026 granted to Marshall A. Nelson on
 Feb. 9, 1988 and Sep. 19, 1989, respectively disclose selective metallic
 transfer foils for selectively transferring metallic foil to xerographic
 images on a receiving substrate such as paper. The transfer sheet
 comprises, in successive layers, a carrier film, a metallic film and an
 adhesive, the adhesive containing a dispersion of 0.5 micron or larger
 particulate material. A method is disclosed for forming images overlaid
 with metallic foil. According to the method of the invention, a sheet
 comprising xerographic images is provided and placed in face-to-face
 contact with a metal transfer sheet, to form a sandwich with the
 xerographic images on the inside. Heat and pressure are applied to the
 sandwich, causing the xerographic images to become tacky and causing the
 metallic foil to selectively adhere to the images. The remainder of the
 transfer sheet is then stripped away from the resulting decorated sheet
 comprising xerographic images overlaid with metallic foil.
 In the preferred embodiment of the invention, the metal transfer sheet is
 provided with an adhesive of high filler content resin which has been
 found to produce good quality transfers to xerographic images produced by
 a wide variety of toners and photocopy machinery.
 U.S. Pat. No. 3,914,097 granted to Donald R. Wurl on Oct. 21, 1975
 discloses a sheet guide and cooling apparatus for preventing curl in
 sheets bearing a developed image, the image being permanently fixed to the
 sheet by application of heat and pressure. The apparatus is positioned to
 have a flat thermally conductive surface establishing a path for the
 sheet, downstream of the fixing area, the path extending in a plane
 substantially coplanar with the plane of sheet travel in the fixing
 station. Vacuum means associated with the surface maintains successive
 incremental portions of a sheet in face-to-face contact with the flat
 surface as it is being guided for at least a predetermined period as the
 sheet moves along the path and furthermore, provides a flow of cooling air
 for the surface.
 U.S. patent application Ser. No. 08/095,639 filed on the same date as the
 instant application discloses a method and apparatus for creating
 simulated photographic prints wherein a mirror image is formed on a
 transparent substrate. The transparent substrate has bonded thereto a
 backing sheet which serves as protection for the powder images on the
 transparent substrate as well as a reflective backing which significantly
 enhances the look of the images. The transparent substrate and backing
 sheet are bonded together by simultaneously passing the two members
 between a pair of heated rollers while simultaneously applying pressure.
 U.S. patent application Ser. No. 08/095,622 filed on the same date as the
 instant application discloses a device for creating simulated photographic
 prints. A transparent substrate to which a reverse reading image has been
 fused is uniformly coated on the image side thereof with a white material
 which serves a the reflective backing.
 U.S. patent application Ser. No. 08/095,016 filed on the same date as the
 instant application discloses a device for creating simulated photographic
 prints. As disclosed therein, a transparent substrate with a reverse
 reading toner image thereon is bonded to a backing sheet using heat and
 pressure provided by a pair of heat and pressure roller members. A second
 pair of rollers is provided downstream of the the heat and pressure roll
 pair receives the lead edge of a simulated photographic print and serves
 to pull the print in order to flatten it. A vacuum holddown transport
 downstream of the puller rolls serves to further flatten the print during
 a cool-down period.
 U.S. patent application Ser. Nos. 08/095,790 and 08/095,136 filed on the
 same date as the instant application discloses a device for creating
 simulated photographic prints wherein a transparent carrier having a
 xerographically formed mirror image fused thereto is bonded to a plastic
 substrate through the use of heat and pressure. The transparent carrier
 and the plastic substrate form the finished print.
 BRIEF SUMMARY OF THE INVENTION
 The primary object of the present invention is to create simulated color
 photographic prints using xerography wherein the print has the look and
 feel of a conventional black and white or color photograph.
 Briefly, the present invention is carried out by first creating a
 multi-color, reverse reading (or mirror) toner image on a transparent
 substrate. The multi-color toner image is xerographically created by
 sequentially forming different color toner images on the transparent
 substrate followed by the use of heat and pressure or other suitable means
 to affix or fuse the multi-color image to the transparent substrate such
 that there is good optical contact at the interface between the
 transparent substrate and the toner. The toner carrying side of the
 transparent substrate is then bonded to a light colored, substrate to
 provide a light color backing for effective reflection of light back
 through the toner image. The process may also be used for creating black
 and white simulated photographic prints.
 Satisfactory results have been obtained by placing the transparent
 substrate containing the toner images, image side up, on a tempered glass
 member and placing a sheet of light colored coated paper material in
 contact with the toner image carried by the transparent substrate. The
 side or surface of the sheet of coated paper material facing the toner
 image is provided with or serves as a carrier for a uniform coating of
 adhesive material for bonding the former to the latter. The tempered glass
 provides a smooth rigid support which rests on an elastomeric pad
 contained in a lower platen of a print making apparatus.
 An adhesive or non-stick member is placed on top of the plastic coated
 sheet material to provide for easy separation of the finished print from
 the print making apparatus. The non-stick member comprises a sheet of
 polyester material having one or both sides thereof coated with an
 adhesive material such as silicone rubber.
 A heated top platen is used to apply pressure and heat to the transparent
 substrate and the translucent sheet through the adhesive member to thereby
 effect bonding of the former to the latter. The resulting print exhibits
 an attractive and brilliant appearance which is more fade resistance and
 durable than commercially available photographic prints. Prints created in
 the foregoing manner have the look and feel of photographic prints but
 appear to have more brilliance. This is thought to be attributable to the
 xerographically formed prints having a lesser minimum density than
 conventional photographic prints resulting in whiter whites A further
 aspect of this invention is that exceptionally good quality prints can be
 more quickly and more cost effectively produced than with conventional
 photographic printing techniques, especially in the case of larger size
 prints. Additionally, this process does not require silver, photographic
 chemicals, or intermediary negatives even when a black and white print is
 created from a color original.
 Still another aspect of the present invention is the capability of creating
 a high quality black and white print from a color original without the
 need to create an intermediary negative as is the case with existing
 photographic methods. This attribute enhances the potential uses of the
 process by making it far more cost effective than photographic processes
 would be in this case.
 Existing color xerographic copier/printer systems can be used for the
 process. Thus, all the resources associated with these products,
 particularly the ones which utilize state of the art electronic devices
 such as film scanners, image composition enhancers, color adjusters and
 editors can be utilized.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION
 While the present invention will hereinafter be described in connection
 with a preferred embodiment, it will be understood that it is not intended
 to limit the invention to that embodiment. On the contrary, it is intended
 to cover all alternatives, modifications and equivalents as may be
 included within the spirit and scope of the invention as defined by the
 appended claims.
 For a general understanding of the features of the present invention,
 reference is made to the drawings. In the drawings, like references have
 been used throughout to designate identical elements.
 FIG. 4 is a schematic elevational view of an illustrative
 electrophotographic copier which may be utilized in carrying out the
 present invention. It will become evident from the following discussion
 that the present invention is equally well suited for use in a wide
 variety of printing systems, and is not necessarily limited in its
 application to the particular system shown herein.
 Turning initially to FIG. 4, during operation of a printing system 9, a
 multi-color original document or photograph 38 is positioned on a raster
 input scanner (RIS), indicated generally by the reference numeral 10. The
 RIS contains document illumination lamps, optics, a mechanical scanning
 drive, and a charge coupled device (CCD array). The RIS captures the
 entire original document and converts it to a series of raster scan lines
 and measures a set of primary color densities, i.e. red, green and blue
 densities, at each point of the original document. This information is
 transmitted to an image processing system (IPS), indicated generally by
 the reference numeral 12. IPS 12 contains control electronics which
 prepare and manage the image data flow to a raster output scanner (ROS),
 indicated generally by the reference numeral 16. A user interface (UI),
 indicated generally by the reference numeral 14, is in communication with
 IPS 12. UI 14 enables an operator to control the various operator
 adjustable functions. The output signal from UI 14 is transmitted to IPS
 12. Signals corresponding to the desired image are transmitted from IPS 12
 to a ROS 16, which creates the output image. ROS 16 lays out the image in
 a series of horizontal scan lines with each line having a specified number
 of pixels per inch. ROS 16 includes a laser having a rotating polygon
 mirror block associated therewith. ROS 16 is utilized for exposing a
 uniformly charged photoconductive belt 20 of a marking engine, indicated
 generally by the reference numeral 18, to achieve a set of subtractive
 primary latent images. The latent images are developed with cyan, magenta,
 and yellow developer material, respectively. These developed images are
 transferred to a final substrate in superimposed registration with one
 another to form a multi-color image on the substrate. This multi-color
 image is then heat and pressure fused to the substrate thereby forming a
 multi-color toner image thereon.
 The printing system 9 is capable of printing conventional right reading
 toner images on plain paper or mirror images on various other kinds of
 substrates as will be discussed hereinafter. Mirror or reverse reading
 images on final substrates are effected through programed use of the UI
 14.
 The features of the printing system hereinabove described are utilized in
 the commercially available 5775.TM. copier.
 With continued reference to FIG. 4, printer or marking engine 18 is an
 electrophotographic printing machine. Photoconductive belt 20 of marking
 engine 18 is preferably made from a polychromatic photoconductive
 material. The photoconductive belt moves in the direction of arrow 22 to
 advance successive portions of the photoconductive surface sequentially
 through the various processing stations disposed about the path of
 movement thereof. Photoconductive belt 20 is entrained about transfer
 rollers 24 and 26, tensioning roller 28, and drive roller 30. Drive roller
 30 is rotated by a motor 32 coupled thereto by suitable means such as a
 belt drive. As roller 30 rotates, it advances belt 20 in the direction of
 arrow 22.
 Initially, a portion of photoconductive belt 20 passes through a charging
 station, indicated generally by the reference numeral 33. At charging
 station 33, a corona generating device 34 charges photoconductive belt 20
 to a relatively high, substantially uniform electrostatic potential.
 Next, the charged photoconductive surface is moved through an exposure
 station, indicated generally by the reference numeral 35. Exposure station
 35 receives a modulated light beam corresponding to information derived by
 RIS 10 having a multi-color original document 38 positioned thereat. RIS
 10 captures the entire image from the original document 38 and converts it
 to a series of raster scan lines which are transmitted as electrical
 signals to IPS 12. The electrical signals from RIS 10 correspond to the
 red, green and blue densities at each point in the original document. IPS
 12 converts the set of red, green and blue density signals, i.e. the set
 of signals corresponding to the primary color densities of original
 document 38, to a set of calorimetric coordinates. The operator actuates
 the appropriate keys of UI 14 to adjust the parameters of the copy. UI 14
 may be a touch screen, or any other suitable control panel, providing an
 operator interface with the system. The output signals from UI 14 are
 transmitted to IPS 12. The IPS then transmits signals corresponding to the
 desired image to ROS 16. ROS 16 includes a laser with rotating polygon
 mirror block. Preferably, a nine facet polygon is used. ROS 16
 illuminates, via mirror 37, the charged portion of photoconductive belt 20
 at a rate of about 400 pixels per inch. The ROS will expose the
 photoconductive belt to record three latent images. One latent image is
 developed with cyan developer material. Another latent image is developed
 with magenta developer material and the third latent image is developed
 with yellow developer material. The latent images formed by ROS 16 on the
 photoconductive belt correspond to the signals transmitted from IPS 12.
 According to the present invention, the document 38 preferably comprises a
 black and white or color photographic print. It will be appreciated that
 various other documents may be employed without departing from the scope
 and true spirit of the invention.
 After the electrostatic latent images have been recorded on photoconductive
 belt 20, the belt advances such latent images to a development station,
 indicated generally by the reference numeral 39. The development station
 includes four individual developer units indicated by reference numerals
 40, 42, 44 and 46. The developer units are of a type generally referred to
 in the art as "magnetic brush development units." Typically, a magnetic
 brush development system employs a magnetizable developer material
 including magnetic carrier granules having toner particles adhering
 triboelectrically thereto. The developer material is continually brought
 through a directional flux field to form a brush of developer material.
 The developer material is constantly moving so as to continually provide
 the brush with fresh developer material. Development is achieved by
 bringing the brush of developer material into contact with the
 photoconductive surface. Developer units 40, 42, and 44, respectively,
 apply toner particles of a specific color which corresponds to a
 compliment of the specific color separated electrostatic latent image
 recorded on the photoconductive surface. The color of each of the toner
 particles is adapted to absorb light within a preselected spectral region
 of the electromagnetic wave spectrum. For example, an electrostatic latent
 image formed by discharging the portions of charge on the photoconductive
 belt corresponding to the green regions of the original document will
 record the red and blue portions as areas of relatively high charge
 density on photoconductive belt 20, while the green areas will be reduced
 to a voltage level ineffective for development. The charged areas are then
 made visible by having developer unit 40 apply green absorbing (magenta)
 toner particles onto the electrostatic latent image recorded on
 photoconductive belt 20. Similarly, a blue separation is developed by
 developer unit 42 with blue absorbing (yellow) toner particles, while the
 red separation is developed by developer unit 44 with red absorbing (cyan)
 toner particles. Developer unit 46 contains black toner particles and may
 be used to develop the electrostatic latent image formed from a black and
 white original document. Each of the developer units is moved into and out
 of an operative position. In the operative position, the magnetic brush is
 closely adjacent the photoconductive belt, while in the non-operative
 position, the magnetic brush is spaced therefrom. In FIG. 1, developer
 unit 40 is shown in the operative position with developer units 42, 44 and
 46 being in the non-operative position. During development of each
 electrostatic latent image, only one developer unit is in the operative
 position, the remaining developer units are in the non-operative position.
 This ensures that each electrostatic latent image is developed with toner
 particles of the appropriate color without commingling.
 It will be appreciated by those skilled in the art that scavengeless or
 non-interactive development systems well known in the art could be used in
 lieu of magnetic brush developer structures. The use of non-interactive
 developer systems for all but the first developer housing would make it
 unnecessary for movement of the developer housings relative to the
 photoconductive imaging surface.
 After development, the toner image is moved to a transfer station,
 indicated generally by the reference numeral 65. Transfer station 65
 includes a transfer zone, generally indicated by reference numeral 64. In
 transfer zone 64, the toner image is transferred to a transparent
 substrate 25. At transfer station 65, a substrate transport apparatus,
 indicated generally by the reference numeral 48, moves the substrate 25
 into contact with photoconductive belt 20. Substrate transport 48 has a
 pair of spaced belts 54 entrained about a pair of substantially
 cylindrical rollers 50 and 52. A substrate gripper (not shown) extends
 between belts 54 and moves in unison therewith. The substrate 25 is
 advanced from a stack of substrates 56 disposed on a tray. A friction
 retard feeder 58 advances the uppermost substrate from stack 56 onto a
 pre-transfer transport 60. Transport 60 advances substrate 25 to substrate
 transport 48. Substrate 25 is advanced by transport 60 in synchronism with
 the movement of substrate gripper 84. In this way, the leading edge of
 substrate 25 arrives at a preselected position, i.e. a loading zone, to be
 received by the open substrate gripper. The substrate gripper then closes
 securing substrate 25 thereto for movement therewith in a recirculating
 path. The leading edge of substrate 25 is secured releasably by the
 substrate gripper. As belts 54 move in the direction of arrow 62, the
 substrate moves into contact with the photoconductive belt, in synchronism
 with the toner image developed thereon. At transfer zone 64, a corona
 generating device 66 sprays ions onto the backside of the substrate so as
 to charge the substrate to the proper electrostatic voltage magnitude and
 polarity for attracting the toner image from photoconductive belt 20
 thereto. The substrate remains secured to the substrate gripper so as to
 move in a recirculating path for three cycles. In this way, three
 different color toner images are transferred to the substrate in
 superimposed registration with one another to form a composite multi-color
 image 67, FIG. 3. According to the invention, the composite toner image
 formed on the photoconductive belt 20 is a right reading image so that
 after transfer thereof, to a transparent substrate in a manner to be
 described hereinafter, the image represents a wrong or reverse reading
 multi-color toner image when viewed from the toner side and is right
 reading when viewed through the transparent substrate.
 The transparent substrate 25 preferably comprises transparent polyester
 material such as Mylar, commercially available from E.I. DuPont. A
 suitable thickness for the transparent substrate for use in forming
 simulated photographic prints using the xerographic process described
 above is approximately 0.0042 inch. The actual thickness of the
 transparent substrate will depend on the xerographic processor which is
 used for making the color images on the transparent substrate. An
 important characteristic of the substrate 25 is that its glass transition
 temperature is substantially above that of the toner materials employed in
 creating the images thereon.
 One skilled in the art will appreciate that the substrate may move in a
 recirculating path for four cycles when under color removal and black
 generation is used and up to eight cycles when the information on two
 original documents is being merged onto a single substrate. Each of the
 electrostatic latent images recorded on the photoconductive surface is
 developed with the appropriately colored toner and transferred, in
 superimposed registration with one another, to the substrate to form a
 multi-color facsimile of the colored original document. As may be
 appreciated, the imaging process is not limited to the creation of color
 images. Thus, high quality black and white simulated photographic prints
 may also be created using the process disclosed herein.
 After the last transfer operation, the substrate gripper opens and releases
 the substrate 25. A conveyor 68 transports the substrate, in the direction
 of arrow 70, to a heat and pressure fusing station, indicated generally by
 the reference numeral 71, where the transferred toner image is permanently
 fused to the substrate. The fusing station includes a heated fuser roll 74
 and a pressure roll 72. The substrate passes through the nip defined by
 fuser roll 74 and pressure roll 72. The toner image contacts fuser roll 74
 so as to be affixed to the transparent substrate. Thereafter, the
 substrate is advanced by a pair of rolls 76 to an outlet opening 78
 through which substrate 25 is conveyed to a processor to be discussed
 hereinafter.
 The last processing station in the direction of movement of belt 20, as
 indicated by arrow 22, is a cleaning station, indicated generally by the
 reference numeral 79. A rotatably mounted fibrous brush 80 is positioned
 in the cleaning station and maintained in contact with photoconductive
 belt 20 to remove residual toner particles remaining after the transfer
 operation. Thereafter, lamp 82 illuminates photoconductive belt 20 to
 remove any residual charge remaining thereon prior to the start of the
 next successive cycle.
 A process according to the invention for forming a simulated photographic
 print which uses the transparency 25 containing the composite, reverse
 reading color image 67 will now be described.
 A print creation apparatus 91 (FIGS. 1-3) including upper and lower platen
 structures 92 and 94, respectively, is provided for producing simulated
 photographic prints using xerography. The lower platen comprises a rigid
 metal plate or base member 96 containing a silicone rubber pad 98 having a
 thickness of approximately 0.5 inch. A flat rigid member 98 supported on
 the silicone rubber pad comprises a 3/8 inch thick, smooth-surfaced,
 tempered glass member 100. The smooth-surfaced tempered glass serves to
 smooth any wrinkles created in the transparency material during the
 imaging process. The upper platen 92 contains a heater structure 102 (FIG.
 3) including heating elements 104.
 The plate or base member 96 is provided with a leg structure 106 for
 supporting the the print making structure 91 on a suitable work surface
 such as a table. The upper platen 92 is hingedly secured via hinge
 structure 108 to an upper platen support structure 110. The support
 structure 110 is, in turn, operatively supported by a post member 112
 received in a cylindrically shaped receiver member 114 forming an integral
 part of the plate or base member 96. The support structure is adapted to
 be pivoted relative to the base member 96 through the use of an arm and
 knob arrangement 115 attached to the support structure 110. The upper
 heated platen can thus be rotated from its home position overlying the
 tempered glass member 100 in order to provide easy access thereto for
 inserting the materials used for print creation.
 In the process of forming a simulated photographic print according to the
 present invention, the transparency 25 containing the toner images is
 placed, image side up, on the tempered glass 100 and a light colored (i.e.
 white or near white) translucent sheet member 116 comprising a coated
 paper material is placed in contact with the toner image on the
 transparent substrate 25.
 The side or surface of the sheet of coated paper material facing the toner
 image is provided with or serves as a carrier for a uniform coating of
 adhesive material 118 which is applied to a thickness of about 0.00025
 inch. A number of adhesives can be selected for use in the present
 invention including materials that will enable the layers to substantially
 permanently bond to each other and not easily separate after extended time
 periods, such as for up to 1 year. Examples of suitable adhesives include
 polyesters, such as those available from Goodyear Chemical and E. I. Du
 Pont, polyvinylacetate, phenolics, epoxy resins, certain polyacrylates
 polycyanoacrylates, cellulosic esters. These adhesives are selected in
 various effective amounts such as for example from about 1 to about 75
 weight percent and preferably from about 0.1 to about 25 weight percent.
 The adhesive layer thickness is generally from about 0.1 micron to about
 25 microns, and preferably from about 1 to about 10 microns or more in
 embodiments, however other effective thickness may be selected. An aerosol
 or spray adhesive has been used with satisfactory results. Specifically, a
 commercially available adhesive sold by the 3M Co. under the name of SUPER
 77 has been used. The aforementioned adhesive is provided in a spray can
 dispenser and, therefore, it can be easily applied to the sheet 116. SUPER
 77 spray adhesive is a high tack, high coverage material and a fast drying
 composition.
 Another suitable adhesive available from the 3M company and is designated
 as 556 Bonding Film. This bonding film comprises 40 to 50% by weight of
 polyterpene resin, 30 to 40% by weight of ethylent-vinyl acetate polymer,
 10 to 20% by weight of polyethylene and 1 to 10% by weight of
 thermoplastic polymer. A layer of this bonding film may be applied
 directly to the sheets 116 or it may be transferred thereto using a
 carrier sheet containing the bonding film as provided by the manufacturer.
 In the case of the latter method, the sheet 116 and the film carrier are
 simultaneously heated while contacting each other for effecting transfer
 of the bonding film to the backing sheet 116.
 An adhesive or non-stick member 120 (FIG. 3) is placed on top of the
 plastic coated sheet member 116. The member 120 comprises a sheet or film
 of polyester or Mylar, commercially available from E.I. DuPont which sheet
 has at least one of its sides coated with an adhesive layer 122 of
 silicone rubber. For sake of convenient use, both sides of the member 116
 can be provided with a layer 122. Thus, with both sides of the polyester
 film coated with silicone rubber, either side thereof can contact the
 sheet member 116. The film has a thickness of approximately 0.004 inch
 while each silicone layer has a thickness of approximately 5 to 10
 microns.
 A suitable coated paper 116 is disclosed in U.S. Pat. No. 5,075,153. As
 disclosed therein, the coated paper comprises a plastic supporting
 substrate such as polyester rather than natural cellulose, with certain
 coatings thereover. Mylar, commercially available from E.I. DuPont is
 preferred as the substrate for the coated sheet 103 in view of its
 availability and lower cost. The coated sheet 116 has a thickness of about
 0.004 inch.
 The hinge mechanism 108 is located centrally of the upper platen 92 and
 serves to allow movement of the upper platen 92 relative to the support
 structure 110, such movement being toward the lower platen 94 for exerting
 pressure on the print forming members supported on the tempered glass
 member 100. Movement of the upper platen is effected through the use of a
 lever arm 126 adapted to be moved in the counterclockwise direction as
 viewed in FIG. 2.
 Pressure variation or adjustment is effected through a pressure adjusting
 knob 128 and suitable linkage, not shown. The adjustment of the knob
 through its associated linkage mechanism serves to control the amount of
 pressure exerted between the upper and lower platens when the lever lever
 arm 126 is actuated.
 An electric cord 130 provides electrical current to the heating elements
 104. The heating elements and thus the operating temperature of the print
 creation structure 91 is controlled via a temperature control 132 carried
 by the support structure 110 as shown in FIG. 2. The operating temperature
 of the device is in the range of 220 to 250.degree. F. The pressure and
 heat are applied for between 15 to 20 seconds, the time being settable via
 a timer knob 134.
 During formation of a simulated photographic print, the transparent
 substrate and coated paper members are subjected to a total pressure in
 the order of 5 to 10 pounds. Since the translucent backing of the print is
 light colored, it exhibits a high degree of light reflectivity when a
 substantial portion of the incident light impinging thereon is directed
 toward the transparent surface. As will be appreciated since the final
 print comprises the translucent backing member and the transparent front
 member, the print may be illuminated from the rear with very pleasing
 results. The resulting simulated photographic print has a total thickness
 of approximately 0.009 inch. Thus, a print 136 created according to the
 present invention has a thickness approximately equal to a conventional
 photograph which is approximately 0.009 inch.
 The transparent substrate 25 without toner images thereon, coated paper
 116, tempered glass 100 and adhesive or non-stick member 120 form a kit
 which can be used for creating simulated photographic prints. To this end,
 the transparent substrate 25 may be used in a machine like the 5775.TM. or
 any other suitable xerographic processor for forming either a black and
 white or color reverse reading image thereon. A commercially available
 heat and pressure device can then be used to adhere a sheet of coated
 paper to the image side of the transparent substrate. A heat and pressure
 device contemplated for making simulated photographic prints using the
 aforementioned kit is currently used for applying decals (decal
 applicator) onto shirts and other articles of clothing. In carrying out
 the invention, once the image is formed on the transparent substrate and
 with the tempered glass member supported on the elastomeric base of the
 heat and pressure applying device, the transparent substrate and coated
 sheet are placed on top of the tempered glass. The adhesive member is
 placed on top of the coated sheet. Heat and pressure are then applied in a
 manner consistent with the normal operation of the decal applicator.
 While creation of simulated photographic prints has been disclosed in
 connection with one specific apparatus it will be appreciated that other
 apparatuses my be utilized for this purpose. For example, the transparent
 substrate and backing sheet may be bonded together using a pair of heat
 and pressure rolls forming a nip through which the substrate and sheet are
 passed.