Abstract:
An apparatus ( 10 ) for processing media contains microcapsules ( 46 ) which contain a first segmented rupturing roller ( 110 ) having multiple roller segments. A second segmented rupturing roller ( 112 ) has multiple roller segments. The roller segments on the first segmented rupturing roller are offset from roller segments on the second rupturing roller. The multiple roller segments rupture unexposed microcapsules ( 40 ) in the media.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates in general to an image-forming apparatus and in particular to producing images by rupturing unexposed microcapsules in a photosensitive media by applying pressure with a magnetically loaded roller.  
       BACKGROUND OF THE INVENTION  
       [0002]     Image-forming apparatus that process photosensitive materials that include microcapsules containing image-forming materials are well known in the art. In this type of apparatus microcapsules are image wise exposed to radiation from an exposure device based on imaging information sent to the exposure device. The photosensitive microcapsules encapsulating the imaging material become hardened when exposed to radiation from the exposure device. Microcapsules that are not exposed by the radiation, and hence do not become hardened, are ruptured by applying pressure. The image-forming material from the ruptured microcapsules is released to begin the development: of the desired image. Image-forming apparatus that employ photosensitive microencapsulated imaging materials are disclosed in U.S. Pat. Nos. 4,399,209; 4,416,966; 4,766,050; 5,783,353; and 5,916,727.  
       SUMMARY OF THE INVENTION  
       [0003]     Briefly, according to one aspect of the present invention an apparatus for processing media contains microcapsules which contain a first segmented rupturing roller having multiple roller segments. A second segmented rupturing roller has multiple roller segments. The roller segments on the first segmented rupturing roller are offset from roller segments on the second rupturing roller. The multiple roller segments rupture unexposed microcapsules in the media.  
         [0004]     Media passes between the first and second segmented roller wherein a force is applied to the independent roller segments in both the first segmented roller and the second segmented roller wherein independent roller segments in both the first segmented roller and the second segmented roller ruptures unexposed microcapsules in the media to form an image within the photosensitive media. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0005]     A more complete understanding of the invention and its advantages will become apparent from the detailed description taken in conjunction with the accompanying drawings, wherein examples of the invention are shown, and identical reference numbers have been used, where possible, to designate identical elements that are common to the figures referenced below:  
         [0006]      FIG. 1  is a schematic, cross sectional view of an imaging apparatus according to the present invention;  
         [0007]      FIG. 2  is a schematic, cross sectional view of an image exposure device used in the imaging apparatus shown in  FIG. 1 ;  
         [0008]      FIG. 3  shows a ferrous load plate and a segmented rupturing roller having magnetic load segments and rupturing roller segments according to the present invention;  
         [0009]      FIG. 4  shows a side view of the ferrous load plate and a segmented rupturing roller shown in  FIG. 3 ;  
         [0010]      FIG. 5  shows a pair segmented rupturing with at least one of the segmented rupturing roller being magnetically loaded according to the present invention;  
         [0011]      FIG. 6  shows a side view of a pair segmented rupturing with at least one of the segmented rupturing roller being magnetically loaded in  FIG. 5 ;  
         [0012]      FIG. 7  shows dual flanged ferrous rupturing roller and magnetic load bar suitable for multi-pass rupturing according to the present invention;  
         [0013]      FIG. 8  shows two segmented rupturing rollers each having an external pressure load roller according to the present invention; and  
         [0014]      FIG. 9  shows two segmented rupturing rollers each having an internal loading pressure according to the present invention. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0015]     The present invention will be directed in particular to elements forming part of, or in cooperation more directly with an apparatus in accordance with the present invention. It is to be understood that elements not specifically shown or described may take various forms well known to those skilled in the art.  
         [0016]     Referring now to  FIG. 1 a  schematic, cross sectional view of an imaging apparatus  10  for exposing photosensitive media  44  utilizing an image exposure device  12  is shown. Photosensitive media  44  is removed from media tray  20  to the preheat station  22 . Once the preheat step is complete the preheated photosensitive media  56  proceeds to the exposure station  24  to be image wise exposed by image exposure device  12 . The exposed photosensitive media  58  is then passed through the microcapsule rupturing device  50  where pressure is applied by microcapsule rupturing rollers  52 . The developed photosensitive media  60  is then passed to the post heating station  32  and from there to the media exit tray  34  as a competed image  62 .  
         [0017]      FIG. 2  shows a schematic, cross sectional view of image exposure device  12  shown in  FIG. 1 . Image exposure device  12  exposes photosensitive media  44 , which has a plurality of microcapsules  46  with an image-forming material  48  encapsulated within the microcapsules  46 . The microcapsules are coated on support base  16  and have an overcoat  14 . Image wise exposure of the selected microcapsules  46  hardens microcapsules  46 . Exposed microcapsules  38  when processed through a microcapsule rupturing device  50  that utilizes microcapsule rupturing roller  52 , shown in  FIG. 1 , are not ruptured. The unexposed microcapsules  46  are ruptured releasing image-forming material  48  encapsulated within the unexposed microcapsules  40  to form an image within the photosensitive media  44 .  
         [0018]      FIGS. 3 and 4  show a segmented rupturing roller  90  having alternating rupturing roller segments  92  and ferrous load segments  94  that are allowed to apply pressure to exposed photosensitive media  58  independently of each other, with exposed photosensitive media  58  between the segmented rupturing roller  90  and the skid plate  72 . The magnetic bar  82  creates a force of attraction between the segmented rupturing roller  90  by means of the ferrous load segments  94  and magnetic bar  82 , which ruptures any unexposed microcapsules  40  within exposed photosensitive media  58  as exposed photosensitive media  58  passes between the segmented rupturing roller  90 , skid plate  72 , and magnetic bar  82 . The ruptured microcapsules release image-forming material  48  encapsulated within the unexposed microcapsules  40  to form an image within the photosensitive media  44 .  
         [0019]     Entrance flange  18  on both ends of the segmented rupturing roller  90  maintain a fixed distance between the segmented rupturing roller  90  and the skid plate  72 . This is necessary so that exposed photosensitive media  58  is allowed to pass between the segmented rupturing roller  90  and the skid plate  72  since the attraction force between the segmented rupturing roller  90  and the magnetic bar  82  would make it difficult to separate the surfaces of the ferrous rupturing roller  42  and the skid plate  72  if they were allowed to contact each other with no exposed photosensitive media  58  present.  
         [0020]      FIGS. 5 and 6  show an upper segmented rupturing roller  110  and lower segmented rupturing roller  112  both having alternating rupturing roller segments  92  which can be made of plastic, and load arms  104  that apply pressure to exposed photosensitive media  58  independently of each other with the load arm  104  pivoting about pivot  96 , with exposed photosensitive media  58  between the segmented rupturing roller  90  and the skid plate  72 . The second magnet  100  and the third magnet  102  creates a force of attraction between them and apply a load to the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  which ruptures any unexposed microcapsules  40  within exposed photosensitive media  58  as exposed photosensitive media  58  passes between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  releasing image-forming material  48  encapsulated within the unexposed microcapsules  40  to form an image within the photosensitive media  44 . The first magnet  98  is polarized such it is in repulsion with second magnet  100  that if exposed photosensitive media  58  varies in thickness a repulsive force will be applied to the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  to compensate. Entrance flange  18  on both ends of the segmented rupturing roller  90  maintain a fixed distance between the segmented rupturing roller  90  and the skid plate  72 . This is necessary so that exposed photosensitive media  58  is allowed to pass between the segmented rupturing roller  90  and the skid plate  72  since the attraction force between the segmented rupturing roller  90  and the magnetic bar  82  would make it difficult to separate the surfaces of the ferrous rupturing roller and the skid plate  72  if they were allowed to contact each other with no exposed photosensitive media  58  present.  
         [0021]      FIG. 7  shows an image exposure device  12  mounted on mounting block  80  that translates along mounting shaft  84 . Dual flanged ferrous rupturing roller  86  rides on mounting shaft  84  as the exposure device  12  is translated along translation shaft  78 , while exposing photosensitive media  58 , and is attracted to magnetic bar  82 . Magnetic bar  82  creates a force of attraction between the dual flanged ferrous rupturing roller  86  and magnetic bar  82 , which ruptures any unexposed microcapsules  40  within exposed photosensitive media  58  as exposed photosensitive media  58  passes between the dual flanged ferrous rupturing roller  86  and magnetic bar  82  releasing image-forming material  48  encapsulated within the unexposed microcapsules  40  to form an image within the photosensitive media  44 .  
         [0022]     Although the embodiments shown thus far have used permanent magnets, electromagnets have some advantages in certain situations. For example, electromagnets allow the amount of force exerted on exposed photosensitive media  58  to be varied. This may be necessary as changes are made at the factory to alter or enhance the materials used for the microcapsules contained in exposed photosensitive media  58 . Using electromagnetic rollers and electromagnetic device to exert pressure on the media also eliminates the need for flanges at each end of the roller. The pressure on the media can be varied with the electromagnetic devices to exert the proper pressure to crush the unexposed microcapsules  40  and the electromagnets could be deenergized to force the rollers apart when new media is loaded. Also, the field on one of the rollers or both of the rollers could be reversed to electro-magnetically force the rollers apart.  
         [0023]     The permanent magnets described in the present invention may be made of a number of different materials known in the art including rare-earth elements. For example, a permanent magnet may be made of a rare-earth material such as neodymium-iron-boron (NdFeB).  
         [0024]      FIG. 8  shows an upper segmented rupturing roller  110  and lower segmented rupturing roller  112  both having rupturing roller segments  92  which can be made of plastic, but not limited to, with exposed photosensitive media  58  between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112 . Upper pressure roller  114  and lower pressure roller  116  both having a deformable rubber layer  106  preferable made from a silicon having a durometor between  30  and  70 . Pressure roller load shaft  118  apply pressure to upper segmented rupturing roller  110  and lower segmented rupturing roller  112  such that rupturing roller segments  92  applies pressure to the exposed photosensitive media  58  independently which ruptures any unexposed microcapsules  40  within exposed photosensitive media  58  as exposed photosensitive media  58  passes between upper segmented rupturing roller  110  and lower segmented rupturing roller  112 . The ruptured microcapsules release image-forming material  48  encapsulated within the unexposed microcapsules  40  to form an image within the photosensitive media  44 .  
         [0025]     Entrance flange  18  on both ends of the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  maintain a fixed distance between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112 . This is necessary so that exposed photosensitive media  58  is allowed to pass between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  since the force between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  would make it difficult to separate the surfaces of the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  if they were allowed to contact each other with no exposed photosensitive media  58  present.  
         [0026]      FIG. 9  shows an upper segmented rupturing roller  110  and lower segmented rupturing roller  112  both having rupturing roller segments  92  which can be made of plastic, with exposed photosensitive media  58  between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112 . Upper segmented rupturing roller  110  and lower segmented rupturing roller  112  both having an internal deformable rubber layer  108  preferable made from a silicon having a durometor between 30 and 70. Pressure roller shaft  118  applies pressure to rupturing roller segments  92  such that rupturing roller segments  92  can apply pressure to the exposed photosensitive media  58  independently which ruptures any unexposed microcapsules  40  within exposed photosensitive media  58  as exposed photosensitive media  58  passes between upper segmented rupturing roller  110  and lower segmented rupturing roller  112 . The ruptured microcapsules release image-forming material  48  encapsulated within the unexposed microcapsules  40  to form an image within the photosensitive media  44 .  
         [0027]     Entrance flange  18  on both ends of the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  maintain a fixed distance between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112 . This is necessary so that exposed photosensitive media  58  is allowed to pass between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  since the force between the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  would make it difficult to separate the surfaces of the upper segmented rupturing roller  110  and lower segmented rupturing roller  112  if they were allowed to contact each other with no exposed photosensitive media  58  present.  
         [0028]     The invention has been described in detail with particular reference to certain preferred embodiments thereof, but it will be understood that variations and modifications can be effected within the scope of the invention.  
       Parts List  
       [0029]    
       
           10  imaging apparatus  
           12  image exposure device  
           14  overcoat  
           16  support base  
           18  entrance flange  
           20  media tray  
           22  preheat station  
           24  exposure station  
           32  post heating station  
           34  media exit tray  
           38  exposed microcapsule  
           40  unexposed microcapsule  
           44  photosensitive media  
           46  microcapsule  
           48  image-forming material  
           50  microcapsule rupturing device  
           52  microcapsule rupturing roller  
           56  preheated photosensitive media  
           58  exposed photosensitive media  
           60  developed photosensitive media  
           62  completed image  
           72  skid plate  
           78  translation shaft  
           80  mounting block  
           82  magnetic bar  
           84  mounting shaft  
           86  dual flanged ferrous rupturing roller  
           90  segmented rupturing roller  
           92  rupturing roller segment  
           94  ferrous load segment  
           96  pivot  
           98  first magnet  
           100  second magnet  
           102  third magnet  
           104  load arm  
           106  deformable rubber layer  
           108  internal deformable rubber layer  
           110  upper segmented rupturing roller  
           112  lower segmented rupturing roller  
           114  upper pressure roller  
           116  lower pressure roller  
           118  pressure roller load shaft