Liquid developing material replenishment system and method

Abstract: A liquid developing material replenishment system wherein an apparatus for developing an electrostatic latent image with a liquid developing material includes a liquid developing reservoir (116) for providing a supply of operative liquid developing material to the developing apparatus, and a liquid developing material supply (126) is coupled to the liquid developing material reservoir (116) for providing a supply of liquid developing concentrate to the liquid developing material reservoir (116) for replenishing the supply of operative liquid developing material in the liquid developing reservoir. A predetermined amount of operative liquid developing material is periodically and/or systematically discharged via port 128 and valve 129 from the liquid developing material reservoir (116) to remove contaminated liquid developing material from the reservoir. In addition, a predetermined amount of liquid developing material concentrate is systematically dispensed from the liquid developing material supply (126) via valve 127 to the liquid developing material reservoir (116) so as to extend the useful life of the operative liquid developing material therein.

Description: This invention relates generally to a liquid developing material-based electrostatographic printing machine, and, more particularly, concerns a development apparatus having a liquid developing material replenishment system for maximizing liquid developing material life in a supply reservoir. Electrostatographic reproduction processes can be adapted to produce multicolor images by altering the basic process for monochrome reproduction in some manner. For example, the charged photoconductive member may be sequentially exposed to a series of color separated images of the original in order to form a plurality of latent electrostatic images. Each color separation is then developed with a developing material containing a complimentary colorant which is the subtractive compliment of the color separated image. Thereafter, each color separated image is superimposed in registration with one another to produce a multicolor image. The fidelity of the final output copy produced by this technique is dependent, to a large extent, on how well the subtractive colorants mix or combine when brought together to reflect the colors found in the original. Conventional electrostatographic imaging techniques previously directed to monochrome image formation have also been extended to the creation of highlight color images, wherein independent, differently colored, monochrome images are created on an output copy sheet. One exemplary highlight color process is described in US-A-4,078,929 issued to Gundlach. As previously noted, conventional electrostatographic imaging processes have also been modified such that the use of liquid developing materials is well known, wherein liquid developing material-based systems have been shown to provide many advantages, and generally produce images of higher quality than images formed with dry toners. One of the key issues associated with multicolor imaging processes, and, in particular, with so-called image-on-image processes, a process which will be described in great detail herein, is contamination of developing material supply reservoirs with developing materials of other colors from previously developed images. That is, developing material of a first color which has been applied to the photoreceptor to produce a first color developed image may separate from the photoreceptor during subsequent processing and may become captured or retrieved by a subsequent development step such that the first color marking particles become incorporated into, and contaminate, the developing material of a different color. It has been found that, even at very low levels, downstream developing material reservoirs may become sufficiently contaminated with upstream toner materials over time such that an unacceptable color shift in the downstream developing material will result. Contamination can also become an issue in other multicolor imaging architectures, including tandem systems wherein back transfer may exist. Clearly, such contamination degrades the color quality of output copies and results in a significant reduction in the useful life of the developer material. This, in turn, generates increased frequency of service calls due to copy quality dissatisfaction and frequently results in the premature replacement of developer material. While this wasteful practice may be justifiable in some situations where copy quality can be restored it is desirable to minimize or eliminate the issue of developer material contamination to reduce the amount of service calls associated therewith and to extend the useful life of developer materials in electrostatic printing machines. Thus, it is desirable to provide a system that compensates for color contamination in developer reservoirs in order to reduce operator intervention which results in machine downtime, and to reduce waste in the form of developing materials as well as unacceptable output copy quality. With particular regard to liquid developing material based imaging processes, it is noted that liquid developing materials generally include a liquid phase, comprising an insulating carrier liquid such as an isoparaffinic hydrocarbon, and a solid phase, comprising marking particles composed of a pigment and a binder, as well as other optional materials, wherein the solid phase marking particles are dispersed or suspended in the liquid phase carrier. In addition, liquid developing materials also typically include a small amount of charge director compound for insuring that the marking particles are uniformly charged to the same polarity, either positive or negative, depending upon the particular application. Charge director compounds are generally ionic compounds capable of imparting an electrical charge to marking particles of a desired polarity and a uniform magnitude so that the particles may be electrophoretically deposited on a charged surface (e.g., the photoreceptive member). The desired charging is achieved by providing a constant optimum concentration of charge director compound in the developing material liquid. In general, when a copy or print is made using liquid developing material, a substantially uniform amount of carrier liquid containing an associated amount of liquid phase charge director is deposited over the entire surface of the photoreceptive imaging surface along with a variable amount of marking particles proportional to the image areas being developed, wherein the marking particles also include an associated amount of solid phase charge director as well as some liquid carrier. Accordingly, during the development of a latent image, a fixed amount of carrier liquid and charge director are depleted from a supply of liquid developing material, along with a variable quantity of marking particles as well as liquid carrier and charge director associated with the marking particles. The depletion amounts of each of these components depends on the amount of image and non-image areas on the latent image being developed. Clearly, the application of liquid developer material to a photoconductive surface for image development results in the depletion of the overall amount of liquid developer in the liquid developing material reservoir. In practice, the liquid reservoir is continuously replenished by the addition of a concentrated dispersion of marking particles and charge director in carrier liquid, as necessary. Thus, in practice, a relatively constant concentration of toner particles, liquid carrier, and charge director is maintained in an operational liquid developing material reservoir. The rate of replenishment of carrier liquid may be controlled by monitoring the overall amount or level of liquid developer in the reservoir, whereas the rate of replenishment of toner particles and/or charge director may be controlled by monitoring the concentration of toner particles or charge directors in the liquid developer in the reservoir. The present invention contemplates a liquid developing material replenishment system, wherein predetermined quantities of liquid developing material concentrate is added to the operational liquid developing material reservoir while a selected amount of contaminated developing material is removed from the liquid developing material reservoir, for eliminating, or at least minimizing the effects of developer material contamination, as described hereinabove. Thus, the replenishing system of the present invention operates to enhance the overall developer life in an operational liquid developing material reservoir by detecting contamination levels in the operational liquid developing material reservoir removing a predetermined amount of contaminated liquid developing material therefrom, and systematically replacing the removed liquid developing material with a predetermined amount of liquid developing material concentrate. US-A-5,231,454 discloses a system for imaging utilizing a liquid developer material including carrier liquid, toner particles and charge director, wherein the system includes a liquid developer reservoir coupled to a developer electrode for developing an electrostatic image with the liquid developer from the reservoir to form a developed image. That system includes an apparatus responsive to the charge level of the liquid developer in the liquid developer reservoir for supplying charge director thereto while maintaining the charge level of the liquid developer in the reservoir. In accordance with one aspect of the present invention, there is provided an apparatus for developing an electrostatic latent image with a liquid developing material, comprising: a liquid developing material reservoir for providing a supply of operative liquid developing material to the developing apparatus; a liquid developing material supply coupled to the liquid developing material reservoir for providing a supply of liquid developing material concentrate thereto, so as to replenish the supply of operative liquid developing material in the liquid developing material reservoir; means for periodically discharging a predetermined amount of operative liquid developing material from the liquid developing material reservoir to remove contaminated liquid developing material therefrom; and means for systematically dispensing a predetermined amount of liquid developing material concentrate from the liquid developing material supply to the liquid developing material reservoir so as to extend the useful life of the operative liquid developing material therein. In accordance with another aspect of the invention, there is provided a multicolor electrostatic graphic printing apparatus according to claim 9 of the appended claims. In accordance with yet another aspect of the present invention, a multicolor electrostatographic printing process wherein a plurality of electrostatic latent images are developed with different colored liquid developing material by means of a plurality of developing apparatus, and further wherein the liquid developing material from a first developing apparatus may become undesirably intermixed with a different colored liquid developing material of a second developing apparatus is provided. The multicolor electrostatographic printing process comprises the steps of, providing a liquid developing material reservoir for supplying operative liquid developing material to the developing apparatus; providing a stored supply of liquid developing material concentrate coupled to the liquid developing material reservoir to replenish the supply of operative liquid developing material in the liquid developing material reservoir; periodically discharging a predetermined amount of operative liquid developing material from the liquid developing reservoir to remove contaminated liquid developing material therefrom; and systematically dispensing a predetermined amount of liquid developing material concentrate to the liquid developing reservoir so as to extend the useful life of the operative liquid developing material therein. The process preferably further includes the step of sensing an unacceptable level of contamination in said supply of liquid developing material. The sensing step preferably includes detecting a color shift in said supply of operative liquid developing material. Preferably, the process further including the steps of: selectively actuating said discharging step in response to detection of an unacceptable color shift in said supply of operative liquid developing material; and selectively actuating said dispensing step in response to actuation of said discharging step. The process may further include the steps of: calculating an amount of operative liquid developing material to be discharged from said liquid developing material reservoir; and calculating an amount of liquid developer material concentrate to be dispensed into said liquid developing material reservoir. Other aspects of the present invention will become apparent as the following description proceeds and upon reference to the drawings, in which: Figure 1 is a schematic elevational view of an exemplary liquid developing material development system incorporating a liquid developing material replenishment system in accordance with an embodiment of the present invention therein; and Figure 2 is a schematic elevational view of an exemplary color electrostatographic printing machine incorporating the replenishment system of Figure 1. For a general understanding of the features of the present invention, reference is made to the drawings, wherein like reference numerals have been used throughout to designate identical elements. It will become apparent from the following discussion that the replenishment system of the present invention may be equally well suited for use in a wide variety of printing machines and is not necessarily limited in its application to the particular single-pass, image-on-image multicolor system described herein. Moreover, while the replenishment system of the present invention will hereinafter be described in connection with a preferred embodiment thereof, it will be understood that the description of the invention is not intended to limit the invention to this preferred embodiment. On the contrary, the description 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. Turning initially to Figure 2, a so-called image-on-image multicolour liquid developing material based electrostatic printing machine is illustrated. Since the construction of such a machine is well known to persons skilled in the art, a detailed description thereof has been omitted, for conciseness. For further information, the reader is referred to US-A-5,722,017, in which the machine is described with reference to Figure 2 thereof. An exemplary apparatus for carrying out the development process utilizing liquid developing materials is depicted schematically at reference numerals 27, 37, 47 and 57 in Figure 2. Each developer apparatus 27, 37, 47 and 57 includes a developing material applicator 28,38,48 or 58 for transporting a different color liquid developing material into contact with the electrostatic latent image on the photoreceptor surface. By way of example, developing material applicator 28 might transport yellow colored liquid developer material, developer material applicator 38 might transport magenta colored liquid developer material, applicator 48 might transport cyan colored liquid developer material, and applicator 58 might transport black colored liquid developer material. Each different color liquid developing material comprises pigmented toner particles and charge directors disseminated through a liquid carrier, wherein the toner particles are charged to a polarity opposite in polarity to the charged latent image on the photoconductive surface such that the toner particles pass by electrophoresis to the electrostatic latent image on photoreceptor belt 100 to create a visible developed image thereon. Each of the developer apparatus 28, 38, 48 and 58 are substantially identical to one another and represent one of various known apparatus that can be utilized to apply liquid developing material to the photoconductive surface. It will be understood that various alternative designs for development systems are disclosed in the art (see, for example, US-A-s 4,733,273; 4,883,018; and 5,355,201, among others), and that the particular liquid developing material development system design disclosed herein will not create a limitation on the present invention. As previously indicated, the liquid developing material generally comprises marking particles and a charge director compound dispersed in a liquid carrier medium. Suitable compositons for the liquid developing material are set out in detail in US-A-5,722,017. After the liquid developing material has been transported into contact with the electrostatic latent image on the photoreceptor surface, the image is developed and a selected amount of liquid developing material, and in particular the liquid carrier portion of the liquid developing material that is deposited on the surface of the photoreceptor belt is preferably reduced. To this end, each developer apparatus system of Figure 2 is provided with metering rolls identified by reference numerals 23, 33, 43 and 53, which are positioned slightly downstream of, and adjacent to respective developing material applicators 27, 37, 47 and 57, in the direction of movement 16 of the photoreceptor 100. As shown, the metering roll 26 may be electrically biased by supplying an AC or a DC voltage thereto for repelling or attracting toner particles present in the liquid developing material on the photoreceptor belt. Preferably the peripheral surface of each metering roller 23, 33, 43 and 53 is situated in close proximity to the surface of the photoreceptor 100 and may or may not contact the surface of the photoreceptor 100 and/or the liquid coating layer thereon. In addition, each metering roller is preferably rotated in a direction opposite the path of movement of the photoreceptor 100 in order to create a substantial shear force against the layer of liquid developing material present thereon. This shear force removes a predetermined amount of excess developing material, in particular carrier liquid, from the surface of the photoreceptor, with the excess developing material eventually falling away from the rotating metering roll for collection in a reservoir or other liquid developer collection and reclaim system, as will be described in greater detail with respect to Figure 1. After image development, the liquid image on photoconductor 100 may be conditioned to compress the image and remove some of the liquid carrier therefrom, as shown, for example, by U.S. Patent No. 4,286,039, among various other patents. An exemplary apparatus for image conditioning is shown at reference numeral 24, 34, 44 and 54, each comprising an electrically biased roller, which may include a porous body and a perforated skin covering. Each image conditioning roller is typically biased to a potential having a polarity which inhibits the departure of toner particles from the image on the photoreceptor surface 100 while compressing the toner particles of the image and further wiping additional liquid carrier therefrom. In operation, the image conditioning roller rotates against the liquid image on belt 100 such that the porous body thereof absorbs excess liquid from the surface of the image through the pores and perforations of the roller skin covering. In an exemplary image conditioning system, a vacuum source (not shown) may also be provided, coupled to the interior of the roller for creating an airflow through the porous roller body to draw liquid away from the surface of the photoreceptor, thereby increasing the percentage of toner solids in the developed image. The optional vacuum source, typically located along one end of a central cavity, draws liquid through the roller surface to a central cavity for depositing the liquid in a receptacle or some other location which permits either disposal or recirculation of the liquid carrier. The porous roller is thus continuously discharged of excess liquid to provide continuous removal of liquid from the image on belt 100. It will be recognized by one of skill in the art that the vacuum assisted liquid absorbing roller described hereinabove may also find useful application in an embodiment in which the image conditioning system is provided in the form of a belt, whereby excess liquid carrier is absorbed through an absorbent foam layer in the belt, as described in U.S. Patent Nos. 4,299,902 and 4,258,115. After image conditioning of the first developed image, the image on belt 100 is advanced to a lamp 26 where any residual charge left on the photoreceptor 100 is extinguished by flooding the photoconductive surface with light from lamp 26. Thereafter, charging imaging and development are repeated for subsequent color separations by first recharging and reexposing the belt 100, whereby color image bitmap information is superimposed over the previously developed latent image. Preferably, for each subsequent exposure an adaptive exposure processor is employed that modulates the exposure level of the raster output scanner (ROS) for a given picture element as a function of the toner previously developed at the picture element site, thereby allowing toner layers to be made independent of each other, as described in commonly owned US-A-5,477,317. The reexposed image is next advanced through a development station and subsequently through an image conditioning station and each step is repeated as previously described to create a multi-layer image made up of yellow, magenta, cyan and black toner particles as provided via each developing station 27, 37, 47 and 57. It should be evident to one skilled in the art that the color of toner at each development station could be provided in a different arrangement than that described herein. After the multi-layer image is created on the photoreceptive member, it may be advanced to an intermediate transfer station where charging device 71 generates a charge for electrostatically transferring the image from the photoconductive belt 100 to an intermediate transfer member 80. Thereafter, the intermediate transfer member continues to advance in the direction of arrow 82 to a transfix nip 94 where the tackified toner particle image is transferred, and bonded to a recording sheet 96 transported through transfix nip 94. The various operations described hereinabove are preferably carried out under the control of a generally conventional microprocessor based control unit (not shown). Such a control unit may be programmed with certain novel functions and graphical user interface features for facilitating the general operation of the electrostatographic printing system. As such, updated data and status information is continually communicated to the control unit for monitoring, and initiating changes in the various operative components of the printing apparatus. All machine functions described herein, including imaging onto the photoreceptor, xerographic functions associated with developing the image and transferring the developed image, paper transport, and finishing operations may be automatically controlled via the control unit. It will be understood that the control unit may be integrated to the developing material replenishment system of the present invention. The foregoing discussion provides a description of certain operations of an electrostatographic printing machine. The detailed structure of an exemplary liquid developer material based development system will be described hereinafter with reference to Figure 1. It will be understood that the development system of the present invention may take many forms, as for example, the type described in previously identified US-A-s 4,733,273; 4,883,018; and 5,355,201 among others, and may be utilized in a multicolor electrophotographic printing machine, or a highlight color machine or numerous other types of electrostatographic imaging systems. Multicolor printing machines may use this type of development unit wherein successive latent images are developed on top of one another to form a composite multicolor toner image which is subsequently transferred to a copy sheet or wherein single color liquid images may be transferred in superimposed registration with one another directly to the copy sheet. In addition, the developed image may be transferred directly to the copy sheet or, in the alternative, may be transferred to an intermediate member prior to transfer to the copy sheet, as described hereinabove. Referring now to Figure 1, an exemplary developer system will be described with the understanding that each developing system 27, 37, 47 and 57 shown, and generally described with respect to the apparatus of Figure 2, are substantially identical thereto. In general, the only distinction between each developer unit is the color of the liquid developing material utilized therein. However, it will be noted that the first developer unit 27 may not benefit from a replenishment system of the type described herein, as that developer unit is generally not susceptible to contamination by colorants of other developer units. As depicted in Figure 1, the developer system includes a developing material applicator 113 coupled to an operational liquid developing material supply reservoir 116. Supply reservoir 116 maintains and provides an operative solution of liquid developing material comprised of liquid carrier, marking particles and charge director compound for application to the surface of photoreceptor 100 via developing material applicator 113. The exemplary developing material applicator 113 includes a housing 114, defining an elongated aperture 119 extending along a longitudinal axis of the housing so as to be oriented substantially transverse to the surface of photoreceptor belt 100, along the direction of travel thereof (as indicated by arrow 16). The aperture 119 provides a path of travel for delivering liquid developing material to the applicator 113 with the gap between aperture 119 and photoreceptor 100 defining a liquid developing material application region, wherein the liquid developing material can freely flow for contacting the surface of the photoreceptor belt 100 to develop the latent image thereon. Thus, liquid developing material is pumped from the supply reservoir 116 to the applicator 113 through supply conduit 118, such that the liquid developing material flows out of the elongated aperture 119 and into contact with the surface of photoreceptor belt 100. An overflow drainage channel (not shown) partially surrounds the aperture 119 for collecting excess developing material which may not have been deposited onto the photoreceptor surface during the development process. The overflow channel is connected to an outlet port 120 for removal of excess or extraneous liquid developing material and, preferably, for directing this excess material back to supply reservoir 116 or to some other collection receptacle whereat the liquid developing material can be collected and the individual components thereof can be recycled for subsequent use. Slightly downstream of and adjacent to the developing material applicator 113, in the direction of movement of the photoreceptor surface 100, is an electrically biased developer metering roller 123, the peripheral surface thereof being situated in close proximity to the surface of the photoreceptor 100. A DC power supply 125 is provided for maintaining an electrical bias on the metering roll 123 at a selected polarity such that image areas of the electrostatic latent image on the photoconductive surface attracts toner for developing the electrostatic latent image. This electrophoretic development process minimizes the existence of marking particles in background regions and maximizes the deposit of marking particles in image areas on the photoreceptor. The developer metering roller 123 is generally rotated in a direction opposite the movement of the photoconductor surface 100 so as to apply a substantial shear force to the thin layer of liquid developing material present in the area of the nip between the developer roller 123 and the photoreceptor 100. This shear force removes a predetermined amount of excess liquid developing material from the surface of the photoreceptor for minimizing the thickness of the liquid developing material on the surface thereof and transports this excess developing material in the direction of the developing material applicator 113. The excess developing material eventually falls away from the rotating metering roll for collection in the supply reservoir or other collection receptacle, as previously described. In operation, liquid developing material is pumped through supply conduit 118, into the elongated aperture 119. The developing material flows in the direction of the photoreceptor 100, filling the gap between the surface of the photoreceptor and the liquid developing material applicator 113. As the belt 100 moves in the direction of arrow 16, a portion of the liquid developing material moves therewith in the direction of the metering roll 123. The metering roll is biased via the DC power supply 125, causing toner particles in the developer material to be attracted to the electrostatic latent image on the photoreceptor. The developing roller 123 also meters a predetermined amount of liquid developing material from the photoconductive surface of belt 100 and transports extraneous liquid developing material away from the photoreceptor. The application of liquid developing material to photoconductive surface 100 via applicator 113, or by any other liquid development system, clearly depletes the overall amount of the operative solution of developing material stored in supply reservoir 116. Marking particles are depleted in the image areas; carrier liquid is depleted in the image areas (trapped by marking particles) as well as in background areas, and may also be depleted by evaporation; and charge director is depleted in the image areas (trapped in the carrier liquid), in the image areas due to adsorption onto marking particles, and in the background areas. In practice, the supply reservoir 116 is continuously replenished, as necessary, by the addition of liquid carrier, marking particles, and/or charge director into the supply reservoir 116. To that end, a replaceable container 126 having a concentrated supply of liquid developing material is typically provided in association with the supply reservoir 116, and coupled thereto, for maintaining the amount of developing material therein at a substantially constant level. It is generally known that, because the total amount of any one of the materials making up the liquid developing material utilized to develop the image varies as a function of the area of the developed image areas and background portions of the latent image on the photoconductive surface, the specific amount of each of these components of the liquid developing material which must be added to the supply reservoir 116 varies with each development cycle. That is, a developed image having a large proportion of printed image area or having substantially a single color will cause a greater depletion of marking particles and/or charge director in the liquid developing material supply tank as compared to a developed image with a small amount of printed image area or of a single color. While the rate of the replenishment of the liquid developing material may be controlled by simply monitoring the level of liquid developer in the supply reservoir 116, in advanced systems the rate of replenishment of the liquid carrier, the marking particles, and/or the charge director components of the liquid developing material is controlled in a more sophisticated manner to maintain a predetermined concentration of the marking particles and the charge director in the operative solution stored in the supply reservoir 116. One exemplary replenishment systems of this nature include systems which measure the conductivity of the operative liquid developing material and add selective amounts of charge director compound to the reservoir as a function of the measured a conductivity, as disclosed in detail in US-A-4,860,924. Alternatively, the amount of carrier liquid, charge director and/or marking particles in a liquid developing material reservoir may be controlled in response to the amount of each component depleted therefrom as a function of the number of pixels making up each developed image. Thus, as the electrostatographic printing machine is used, liquid developing material is depleted therefrom and must be replenished. In addition, it has been found that liquid developing materials have a very delicate chemical balance which is easily upset by factors such as excess replenishment, aging, contamination, color intermixing, selective constituent removal during electrophoretic development, or simply heavy use. If this chemical balance is lost, poor imaging results and the entire contents of the liquid developer material supply reservoir must be replaced. Further, as the chemical balance of the liquid developer material varies with use, the contrast in color balance of the finished output copies may vary to an unacceptable level. In order to solve this problem and to provide a supply of liquid developer material having an extended useful life, the present invention contemplates the periodic discharge of contaminated or otherwise unacceptable liquid developing material from the liquid developing supply reservoir 116 along with replenishment of the discharged material. The approach provided by the replenishment system of the present invention, as illustrated in Figure 1, includes, as previously indicated, a concentrate reservoir bottle 126 for providing a replenishing supply of fresh liquid developing material concentrate to the operative liquid developing material reservoir 116. The concentrate supply bottle 126 is coupled to the operative liquid developing material reservoir 116 via a supply pipe having a supply valve 127 interposed therein. In addition, the operative liquid developing material reservoir is provided with an exit port 128 situated at an appropriate position in an exterior wall of the reservoir 116. The exit port is coupled, via a drain pipe having an egress valve 129, to a collection sump (not shown) or other repository. In accordance with the most basic concept of the present invention, a system is provided for periodically discharging a predetermined amount of operative liquid developing material from the liquid developing material reservoir 116 in order to remove unacceptably contaminated liquid developing material therefrom. In its simplest implementation, this discharge process may be initiated periodically, as a function of time or the number of images developed or any other relevant factor. However, in a more sophisticated implementation contemplated by the present invention, initiation of the process of discharging of liquid developing material will be directly related to the level of contamination in the reservoir 116. To that end, a sensing device 130, for example an optical sensor, may be provided for monitoring the color of the liquid developing material in the reservoir 116 and selectively controlling. Although sensing device 130 is shown in Figure 1 in a position so as to monitor the liquid developing material being transported from the liquid developing material reservoir 116 to the developing material applicator 113 via an optically transmissive window in supply conduit 118), it will be understood by those of skill in the art that various well known sensing devices may be utilized to detect unacceptable color shifts in the liquid developing material, including devices which are submerged in the liquid developing material reservoir 116, or devices which monitor light attenuation across the volume of the reservoir 116. Sensor 130 is connected to a controller 132 which may include the machine controller, wherein the sensor 130 produces a signal upon detection of an acceptable color shift indicative of undue contamination caused by toner particle intermixing among other factors. This signal is then transmitted to controller 130 for actuating valves 127 and 129 to control the flow of waste liquid developing material to be discharged from the liquid developing material supply reservoir 116 as well as the flow of replenishing liquid developing material delivered into the liquid developing material supply reservoir 116 from container 126. It will be understood that valves 127 and 129 can be replaced by pump devices or any other suitable flow control mechanisms as known in the art. It is noted that the flow of waste developing material discharged from reservoir 116 may be directed to a waste pump, or in the alternative, to the operative supply of black liquid developing material: That is, since black color developing material is actually made up of Cyan, Yellow and Magenta, the black developing housing is least likely to attain an unacceptable color shift due to contamination by differently colored developers. Further, by causing the Cyan, Yellow and Magenta housings to be discharged at approximately the same rates, directing the waste to the black supply reservoir can maintain the color thereof within an acceptable range. Thus, in accordance with the present invention, as the contamination level in the liquid developing material reservoir exceeds a predetermined amount, i.e. as dictated by the sensor 130, a predetermined amount of contaminated liquid developing material is discharged from the reservoir 116 via exit port 128 and a second predetermined amount of fresh liquid developing material concentrate is discharged into the reservoir 116 in order to replenish the supply of liquid developing material therein. Control of the liquid developing material replenishment system of the present invention requires a predetermined knowledge of acceptable color shift (ΔE) which is permissible in the printing system, with the understanding that acceptable color shift can vary depending on system parameters and color fidelity requirements. However, assuming a given allowable color shift, one can determine the allowable contamination level of the transferred mass per unit area (TMA). Thereafter, assuming that the transferred developer mass per unit area is related to the developed mass per unit area (DMA), one can further calculate the allowable toner concentration contamination level from the allowable developed mass per unit area contamination. This, in turn, permits the calculation of the amount of liquid developing material which must be discharged from the operational liquid developing material reservoir as well as the amount of liquid developing material concentrate required to be replenished into the reservoir. In this way, the color of the liquid developing material in the reservoir 116 is corrected before the printed color is unacceptably contaminated. The foregoing process represents one of various exemplary processes for providing a control system for the replenishment system of the present invention. It is assumed that the selected control process can be reduced to a programmable algorithm which can be operated via controller 132 to yield extended liquid developing material life in accordance with the present invention. It is noteworthy that alternative methods of achieving the desired result of extended liquid developer material life may be derived from the basic "discharge and replenish" concept of the present invention. One particular alternative embodiment contemplated by the present invention involves the use of color corrected liquid developing material as the replenishing liquid developing material which is provided to the operational liquid developing material reservoir 116 in order to counter the effects of cross-contamination due to intermixing of liquid developing material from an upstream developer system in the liquid developing material reservoir of a downstream developer system. Thus, it has been found that one possible method of extending the usable life of liquid developing material in a reservoir is to replenish the contaminated liquid developing material reservoir, which has been contaminated by a second color liquid developing material, with a liquid developing material of a third color to correct for the color contamination. For example, if the color order of the respective developing systems in a liquid developing material-based system is yellow, magenta, cyan and black (Y, M, D, K), it may be advantageous to correct for contamination of the magenta liquid developing material reservoir with yellow liquid developing material by adding a small amount of cyan liquid developing material to the magenta liquid developing material reservoir. Thus, the present intention also contemplates that the liquid developing material provided in supply container 126 may be some "color-corrected" liquid developing material containing a major amount of colorant corresponding to the color in the operational liquid developing material reservoir, in combination with a minor amount of at least a second colorant which would tend to correct for the color shift caused by the contaminating liquid developing material. Alternatively, each supply container 126 containing a different colorant can be coupled to each liquid developing material reservoir 116 with replenishment thereof being provided by a selective mixture from each supply container. In review, it should be clear from the foregoing description that the liquid developing material replenishment system of the present invention is operative to remove a predetermined amount of contaminated liquid developing material from an operative liquid developing material reservoir, and systematically replacing the removed the liquid developing material with a predetermined amount of liquid developing material concentrate from a liquid developing material supply. A sensing device is provided for detecting an unacceptable level of contamination in the operational liquid developing material reservoir, as may result from the release of color toner from a first color developed image by a subsequent second color development process.

Claims: An apparatus for developing an electrostatic latent image with a liquid developing material, comprising: a liquid developing material reservoir (116) for providing a supply of operative liquid developing material to said developing apparatus; a liquid developing material supply (126) coupled to said liquid developing material reservoir (116) for providing a supply of liquid developing material concentrate thereto so as to replenish the supply of operative liquid developing material in said liquid developing material reservoir (116); means (132, 127) for systematically dispensing a predetermined amount of liquid developing material concentrate from said liquid developing material supply (126) to said liquid developing material reservoir (116) so as to extend the useful life of said operative liquid developing material therein; characterised in that the apparatus further comprises means (132, 128, 129) for periodically discharging a predetermined amount of operative liquid developing material from said liquid developing material reservoir (116) to remove contaminated liquid developing material therefrom. The apparatus of claim 1, further including sensing means (130) for detecting an unacceptable level of contamination in said supply of liquid developing material. The apparatus of claim 2, wherein said sensing means (130) includes means for detecting a color shift in said supply of operative liquid developing material, and preferably includes a multiwavelength light attenuation sensing device. The apparatus of claim 2 or 3, further including control means (132) coupled to said sensing means (130) for selectively actuating said discharging means (132, 128, 129) and said dispensing means (132, 127). The apparatus of claim 4, wherein said control means (132) includes: means for calculating an amount of operative liquid developing material to be discharged from said liquid developing material reservoir (116); and means for calculating an amount of liquid developer material concentrate to be dispensed into said liquid developing material reservoir (116). The apparatus of any of the preceding claims, wherein said supply of operative liquid developing material includes marking particles having a first colorant. The apparatus of claim 6, wherein supply of liquid developing material concentrate includes marking particles having the first colorant and marking particles having at least a second colorant for at least partially offsetting contamination of said operative liquid developing material due to contamination caused by marking particles of a third colorant. The apparatus of any of the preceding claims, further including: means for measuring conductivity of said operative liquid developing material in said reservoir (116); and means, responsive to said conductivity measuring means, for adding charge director to said liquid developing material reservoir (116). A multicolor electrostatographic printing apparatus including a plurality of development subsystems (27, 37, 47, 57) for developing electrostatic latent images with different colored liquid developing material, wherein liquid developing material from a first development subsystem may become undesirably intermixed with a different colored liquid developing material of a second development subsystem when the printing apparatus is in use, wherein at least one development subsystem comprises the developing apparatus of any of the preceding claims. A multicolor electrostatographic printing process, wherein a plurality of electrostatic latent images are developed with different colored liquid developing material by means of a plurality of developing apparatuses during the operation of the printing process, and further wherein the liquid developing material from a first developing apparatus may become undesirably intermixed with a different colored liquid developing material of a second developing apparatus, comprising the steps of: providing a liquid developing material reservoir (116) for supplying operative liquid developing material to said developing apparatus; providing a stored supply of liquid developing material concentrate (126) coupled to said liquid developing material reservoir (116) to replenish the supply of operative liquid developing material in said liquid developing material reservoir (116); periodically discharging a predetermined amount of operative liquid developing material from said liquid developing material reservoir (132, 128, 129) to remove contaminated liquid developing material therefrom; and systematically dispensing a predetermined amount of liquid developing material concentrate to said liquid developing material reservoir (132, 127) so as to extend the useful life of said operative liquid developing material therein.

Inventors: CARUTHERS EDWARD B JR, GIBSON GEORGE A, LARSON JAMES R, STOVER RAYMOND W, CARUTHERS, EDWARD B. JR., GIBSON, GEORGE A., LARSON, JAMES R., STOVER, RAYMOND W.
Applicants: XEROX CORP, XEROX CORPORATION
Application year: 1997
Main classification: G03G15
IPC codes: G03G15