Abstract:
A printer comprising a base module having a main drive element and a print zone, a main module back plane coupled with the base module, a machine base rail system coupled to the base module, and an expansion module releasably coupled to the machine base rail system between an operating position and a removed position.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of U.S. Provisional Application No. 60/847,567 filed on Sep. 27, 2006. The disclosure of the above application is incorporated herein by reference. 
     
    
     FIELD  
       [0002]     The present disclosure relates to ink jet printers and, more particularly, relates to industrial ink jet printers having a modular construction.  
       BACKGROUND  
       [0003]     The statements in this section merely provide background information related to the present disclosure and may not constitute prior art.  
         [0004]     Industrial ink jet printing systems are designed to serve users with specific and varied requirements. Some users may only need a relatively simple configuration consisting of an unwind, print zone, ink curing zone and a rewind spindle, while other users would also require a web cleaner, web pretreatment zone, a web guide, additional curing zones or many other application specific modules. In addition, digital printing system design must make use of highly accurate backplane surfaces to which the web transport elements (drive rollers, idlers, dancer rolls, etc) and print hardware are mounted to. In order to meet the highly varied needs of all users in the marketplace, it is necessary to create many custom printing systems, each one special, highly engineered and not cost effective enough to wider markets.  
         [0005]     As an alternative, one very large system could be designed that had space for all possible configurations, features and options. This approach would reduce the engineering effort, and standardize the design and construction. However, it would force all users to purchase a machine that is potentially much larger and more expensive than they need, again not cost effective. From an engineering standpoint, it would also necessitate a very large back plane, which is more difficult to keep in a true plane, resulting in negative performance characteristics.  
         [0006]     Previous work in digital press design revolved around custom printer design specific to a user, or a design lacking the options or features that users need. Digital printing systems lack the ability to cost effectively add or change features and options for their varied users.  
       SUMMARY  
       [0007]     The present teachings are superior to methods previously used because it uses a modular approach to digital printer system design. The design comprises a base module containing the main drive elements and print zone, common on all print systems. This module is made up of the main module back plane, and a machine base “rail system” which would allow additional modules to be added before or after the base module. The rail system is expandable and provide for easy drop in and bolt up add on modules. Add on modules are designed for unwinding substrates, web cleaning, corona treating, static control, pre-treatment, coating, curing, graphic printing, additional curing, laminating, die cutting, waste removal, serial number printing, sheeting, rewind, or any other feature or further process that the digital market required.  
         [0008]     This approach standardizes the designs significantly, allows for easy expansion of features, maintains appropriate cost profiles in that users pay for the modules they need, and not for modules or features they do not. It also allows changes to be made in the field, as user&#39;s needs changes or expand. Finally, from an engineering standpoint, smaller backplanes are easier and more cost effective to manufacture. Additionally, when a design change is necessary, it would affect only the design of that module, and would not affect the entire printer system.  
         [0009]     Further areas of applicability will become apparent from the description provided herein. It should be understood that the description and specific examples are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. 
     
    
     DRAWINGS  
       [0010]     The drawings described herein are for illustration purposes only and are not intended to limit the scope of the present disclosure in any way.  
         [0011]      FIG. 1  is a schematic view illustrating a modular ink jet printer system according to some embodiments of the present teachings; and  
         [0012]      FIG. 2  is a schematic view illustrating a modular ink jet printer system according to additional embodiments of the present teachings. 
     
    
     DETAILED DESCRIPTION  
       [0013]     The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.  
         [0014]     The present teachings use a modular approach to designing and building digital printers for industrial use. According to these teachings, print modules are designed for specific purposes and added to the expandable base support. The base support can consist of a main backplane or backplanes and a rail system that can be expanded to accept removable modules at various positions along the base support. In those embodiments using a rail system, the rail system provides basic support and alignment for modules  12 , both during initial build and during field modifications. Options and features can be organized logically, placed into the rail system, aligned and affixed in place using standard fasteners and fastening methods. One or more printing functions are designed into a module depending on the characteristics required. Examples may include a module that handles the unwind spindle and tension dancer functions, a module that handles web cleaning and corona treatment and modules that include specific UV lamps from outside vendors. If a change to a configuration is needed, or a new capability is desired, the existing modules can conveniently be loosened and slid down or removed to make room for the new module. With this expandable rail system, feature upgrades can be done with minimal effort.  
         [0015]     With particular reference to the figures, a modular ink jet printer system  10  is provided having a plurality of modular components or modules  12 . Each of the plurality of modules  12  can be either stand alone modules that are arranged inline and optionally mounted together with tie bars  14  ( FIG. 1 ), or can be smaller subsections that are attached to a main framework or base support  16  ( FIG. 2 ).  
         [0016]     With reference to  FIG. 1 , each of the plurality of modules  12  can be coupled to tie bars  14  via conventional fasteners or coupling devices (not shown). However, it should be understood that tie bars  14  can be used to properly and accurately position each of the plurality of modules  12  related to adjacent modules  12  to achieve a reliable and accurate printing and/or processing methodology. Therefore, in some embodiments, tie bars  14  can be manufactured to a tolerance sufficient to achieve this desired module-to-module spacing. During operation, individual modules  12  of modular ink jet printer system  10  can be removed and replaced to achieve a modified printer operation.  
         [0017]     With reference to  FIG. 2 , in some embodiments, each of the plurality of modules  12  can be coupled to base support  16  via conventional fasteners or coupling devices  18 . In this regard, base support  16 , being a single integral member, provides a consistent mounting structure having unchanging predetermined mounting locations. These mounting locations receive each of the plurality of modules  12  and are arranged such that they define a relative position between adjacent modules  12  that achieve a reliable and accurate printing and/or processing methodology. Therefore, in some embodiments, tie bars  14  can be manufactured to a tolerance sufficient to achieve this desired module-to-module spacing. During operation, individual modules  12  of modular ink jet printer system  10  can be removed and replaced to achieve a modified printer operation.  
         [0018]     In some embodiments, as illustrated in  FIG. 2 , each of the plurality of modules  12  can be mounted or other interfaces with base support  16  using standard fasteners  18 . In some embodiments, locating pins  20  can be used to locate a module  12  upon base support  16 . In this regard, locating pin  20  can extend from either base support  16  or module  12  and be received in a tolerance receiving aperture  22 . If modules  12  use flat plate construction, the plates of modules  12  can be constructed using structurally sound flat plate material (usually steel or aluminum) and cross members used to span across the plates. The cross members must be manufactured accurately so that their lengths are consistent in order to achieve parallelism between the plates. The plates are manufactured with the correct holes, slots, cut outs and interfaces for bearings, shafts, motors, rollers and other necessary components.  
         [0019]     In some embodiments, it is desirable to position the plurality of modules  12  accurately to base support  16  and to other modules  12  before securing them. To this end, such positioning and/or alignment of modules  12  can be accomplished by machining a receptacle (such as a locating aperture  30  that could include a circular hole, half-hole, or other shape) into the edge of module  12 . A corresponding single pin  32  can extend from base support  16  and communicate with locating apertures  30  from multiple modules  12  as illustrated in  FIG. 2 . Such positioning can be completed prior to fastening of modules  12  to base support  16 .  
         [0020]     Hurdles overcome within this design include ensuring accurate module placement, designing modules that contain complementary functionality, and standardizing modules  12  so that they can be changed out in the field easily, without re-positioning the remaining modules.  
         [0021]     Modular ink jet printer system  10  is being implemented to successfully adjust the digital print equipment to the exact customer needs without having to have multiple single purpose machines. It will also provide for easy field upgrades for customers that find new products to print or require new or additional components.  
         [0022]     In some embodiments, a base module or primary module can be used that is larger than other modules of the assembly, as it may contain most critical drive and print functions. The remaining modules or expansion modules can vary in size, depending on the design requirements for that specific module. All modules are designed to place operator functions in an ergonomic zone, limiting the overall height to a practical range.  
         [0023]     Electrical, mechanical, piping, pneumatic, other machine utilities and signals are routed to the necessary modules using expandable cabinetry and expandable ducting. Very robust brackets and connecting bars will be utilized to ensure that backplanes of modules  12  being assembled stay truly planar on the base rail system.