Abstract:
What is contemplated is a printing cylinder washer having a removable or portable drive assembly, or a series of portable drive assemblies of different lengths to accommodate different sizes of print rollers. The drive assemblies have a drive mechanism enabled by a dynamic flow of cleaning solution within the washer reservoir. What is also contemplated is the use of an elevation system, an agitation platform, under-immersion spray bars, an ultrasonic wave cleaning system, and a hatch or door equipped with a thermal breaker in conjunction with the hydro-driven portable drive assembly. What is also contemplated is a method of washing printing rollers within the above-described printing cylinder washer by aligning a nozzle with the drive assembly.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a divisional of co-pending U.S. patent application Ser. No. 11/948,580 filed Nov. 30, 2007, which is hereby incorporated herein in its entirety by reference. 
     
    
     FIELD OF THE DISCLOSURE 
       [0002]    The present disclosure relates to an immersion cleaner for print rollers, and more specifically, to a printing cylinder washer having a drive assembly in the immersion cleaner with a drive mechanism enabled by a directional flow of circulating cleaning solution in the reservoir. 
       BACKGROUND 
       [0003]    Mechanical parts collect dirt, abrasion residue, used grease, and other debris during normal operation. Rollers in the printing industry are used to lick ink or other chemicals from reservoirs and spread these chemicals across substrates in a well-defined pattern found on other rollers. Print rollers progressively collect dirt, loose particles, and even dry ink. Five different technologies are know in the industry: manual parts washing, automatic parts washing, spray-under-immersion cleaning, soaked parts washing and abrasive blast cleaning using a variety of different media. Washing print rollers can be done manually using a sponge, a brush, or a towel or facilitated using automated devices. Some devices operate onsite without the need for the removal of the print roller, while others operate offsite once the print roller is removed and transported to a print roller cleaner. The current disclosure relates to automatic parts washers using immersion cleaning with or without spray-under-immersion cleaning and soak washing under immersion. 
         [0004]    A parts washer is an apparatus that cleans parts, either individually or in groups, including but not limited to cleaning of machinery and machine parts or print rollers. Immersion cleaners are a subgroup of parts washers where mechanical parts, such as print rollers, are immersed in a cleaning solution during cleaning operations. The core technology associated with immersion cleaners is not unlike the technology associated with the immersion cleaning of automobile parts at repair shops. Some parts washers use an aqueous cleaning solution to dissolve and remove grease, carbon, resins, tar, inks, and other debris. These parts washers use water, soap, and/or detergents, either common or proprietary. Other more aggressive parts washers use hydrocarbon-based solvents or other solvents to degrease and wash parts. Cleaning solutions may in some cases be abrasive, solvent based, or corrosive and require confinement and ultimately recycling. Even if water-based solutions are used in the immersion process, the washed residue can be abrasive, solvent based, or corrosive and require confinement, filtration, and processing. 
         [0005]    Print rollers are generally heavy cylindrical parts with somewhat delicate printing surfaces having two supporting ends also of cylindrical shape. Rollers of different lengths and radii must be used in the printing industry, often in tandem on a single printing press. Print roller washers must accommodate differently sized rollers with different lengths, radii, and weights. Cleaning requires relative movement of the cleaning solution and the surface of the printing roller to help with the dissolution of dirt particles in the cleaning solution. The most efficient way to move the roller in the cleaning solution is to allow the roller to roll creating a maximum velocity of cleaning solution at the surface. Other relative movements are difficult because of the inertia of the roller in the fluid. To rotate the print rollers, a driving means is require, in the prior art, mechanically driven means are used, either via chains, belts, connected to a motor. Unlike the cleaning solution that can easily be regenerated, the driving means and motor must periodically be cleaned. What is needed is a driving means that does not require any periodic maintenance or cleaning. Another common problem of the prior art is the incapacity to clean both the entire printing surface and the ends, the prior art systematically holds the print roller either on wheels located at a position along the printing surface or by the ends. In both cases, lines or surfaces cannot be effectively cleaned. What is needed is a support system, that reduces cleaning interferences by allowing the cleaning solution to reach the entire external surface of the print roller during washing operations. One model of immersion print roller washer from the prior art, described in U.S. Pat. No. 5,291,827, disclose a large, rectangular reservoir where the print roller is immersed in a cleaning solution. The sides of the reservoir are equipped with a lowering and holding mechanism. A roller chain driven drive mechanism attached to support rollers and rotates the print rollers to be washed. Obvious disadvantages of this system includes the incapacity to accommodate narrow print rollers and the need to use a drive mechanism partly immersed in the cleaning solution that pulls cleaning solution out of the reservoir and ultimately degrades a non-immersed motor. 
         [0006]    One model of immersion print roller washer from the prior art, described in U.S. Pat. No. 5,291,827, disclose a large, rectangular reservoir where the print roller is immersed in a cleaning solution. The sides of the reservoir are equipped with a lowering and holding mechanism. A roller chain driven drive mechanism is attached to support rollers and rotate the print rollers to be washed. Obvious disadvantages of this system includes the incapacity to accommodate narrow print rollers and the need to use a drive mechanism partly immersed in the cleaning solution, that pulls cleaning solution out of the reservoir and ultimately degrades a non immersed motor. 
         [0007]    A more recent model from the prior art, described in U.S. Pat. No. 5,636,571, is equipped with a large, open reservoir to accommodate a plurality of rollers attached to the top surface of the reservoir. Rail systems can be adjusted to accommodate narrow print rollers and the drive mechanism is external to the reservoir and supports part of the print rollers held outside of the cleaning solution. The obvious disadvantages of this system includes the incapacity to clean one of the critical portion of the print roller: the supporting ends. This device also requires a top cover to prevent splashing or evaporation of fumes during the washing process. 
         [0008]    In another type of print roller immersion washer described in U.S. Pat. No. 5,490,460, print rollers are fully immersed in cleaning solution in an reservoir but are placed on rotating pegs in contact with the delicate printing surface of the print roller while the driving mechanism rotates the roller in the cleaning solution. A single belt-based drive mechanism is shown and connected with a motor located outside of the reservoir. Obvious disadvantages of this device is the need for sets of wheels and the incapacity to clean a print roller without resorting to a full support on the printing surface over wheels near the extremity of the print roller. 
         [0009]    What is needed is a immersion cleaner for print rollers capable of cleaning the entire print roller without damaging the printing surface of the print rollers. What is also needed is an immersion cleaner capable of rotating print rollers without the need for a roller chain or a strap in the interface between the cleaning solution and the dry portion of the printing cylinder washer. 
       SUMMARY 
       [0010]    What is contemplated in one aspect of the present disclosure is a printing cylinder washer having a removable or portable drive assembly, or a series of portable drive assemblies of different lengths to accommodate differently sized print rollers. The drive assemblies have a drive mechanism enabled by a dynamic flow of cleaning solution within the washer reservoir. What is also contemplated is the use of an elevation system, an agitation platform, under-immersion spray bars, an ultrasonic-wave cleaning system, and a hatch or door equipped with a thermal breaker in conjunction with the hydro-driven portable drive assembly. What is also contemplated is a method of washing printing rollers within the above-described printing cylinder washer by aligning a nozzle with the drive assembly. The use of a plurality of small friction tabs also improves the contact of the cleaning solution with the entire printing surface. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    Certain embodiments are shown in the drawings. However, it is understood that the present disclosure is not limited to the arrangements and instrumentality shown in the attached drawings, wherein: 
           [0012]      FIG. 1  is a perspective view of the printing cylinder washer without the drive assembly shown with an open reservoir door with the support table in a high position and illustrated in dashed line in a low position according to an embodiment of the present disclosure. 
           [0013]      FIG. 2  is a perspective view of the printing cylinder washer with the reservoir door in a closed position. 
           [0014]      FIG. 3  is a front left perspective view of the printing cylinder washer of  FIG. 2  shown from a different point of view to illustrate the pumping and filtration system according to an embodiment of the present disclosure. 
           [0015]      FIG. 4  is a side view of the printing cylinder washer of  FIG. 3  according to an embodiment of the present disclosure. 
           [0016]      FIG. 5  is a functional diagram of the printing cylinder washer with drive assembly and a printing cylinder according to an embodiment of the present disclosure. 
           [0017]      FIG. 6  is a perspective view of the drive assembly with a printing cylinder according to an embodiment of the present disclosure. 
           [0018]      FIG. 7  is a top view of the drive assembly as shown in  FIG. 6 . 
           [0019]      FIG. 8  is a perspective view of the printing cylinder washer shown with an open reservoir door and the support table in a high position with the drive assembly and a printing cylinder in the high position according to an embodiment of the present disclosure. 
           [0020]      FIG. 9  is a block diagram of a method of washing a printing cylinder in a printing cylinder washer as contemplated in one embodiment of the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0021]    The present invention is not limited to the particular details of the device depicted, and other modifications and applications may be contemplated. Further changes may be made in the device described herein without departing from the true spirit of the scope of the disclosure. It is intended, therefore, that the subject matter of the above depictions be interpreted as illustrative, not in a limiting sense. 
         [0022]      FIG. 8  shows a perspective view of the printing cylinder washer  1  including the drive assembly  100  positioned on a support table  11 .  FIG. 1  shows the same perspective view of the printing cylinder washer  1  but without the drive assembly  100  to illustrate how the reservoir  10  with a support table  11  can be raised or lowered within the reservoir  10  from a low position (shown by dashed lines) and a high position as depicted. One of ordinary skill in the art will recognize that the support table  11  can be moved by way of mechanical, hydraulic, pneumatic, and electro-mechanical means, including but not limited to a sliding rail or an elevator system  14  located behind the support table  11  activated from the command bay  17  for raising or lowering the support table  11 . It is also contemplated that the use of a fixed support table  11  with retractable or adjustable legs positioned either directly on the bottom  50  of the reservoir  10  or on an edge (not shown) made on the sidewalls  7  of the reservoir  10  forming a collecting pan. 
         [0023]    In  FIG. 1 , the support table  11  is shown as a grate that allows the flow of cleaning solution  39  (shown in  FIG. 5 ) within the reservoir  10  such that debris and other particles to drop down into the cleaning solution  39  during cleaning and fall to the lower parts of the washer  1  where, in a preferred embodiment, debris can be funneled into a bend  48  formed in the bottom  50  located next to a drain  4  with a control valve  5  as shown in  FIG. 8 . A debris collection system is shown that operates under the principle that any debris or particle with a density superior to the cleaning solution  39  drops under its own weight to the lower parts of the reservoir  10  between washing cycles. Alternately, particles or debris of lesser density than the cleaning solution  39  rise to the surface where they can be filtered by an external filter  27  before cleaning solution  39  is cycled back into the reservoir  10 . 
         [0024]      FIG. 8  shows a printing cylinder washer  1  with a reservoir  10  that defines a volume between the bottom  50  and the sidewall  7  in which a cleaning solution  39  and a support table  11  are disposed. The washer  1  also includes a pump  25  having an inlet  44  in fluidic contact with the cleaning solution, a first outlet  29  connected to a spray bar  46 , and a second outlet  30  connected to a directional nozzle  45  as shown in  FIG. 5 . The reservoir  10  also includes a top door  9  shown as a flat, hinged door having an automated opening system  19  as shown in the open position in  FIG. 5  and in the closed position in  FIG. 2 . 
         [0025]    The top door  9  is equipped with a lift bar  19  attached to a thermal breaker  23 . A mechanical system in the lift column  18  allows the lift bar  19  to slide up the slide  34  to pull the door  9  on its hinge  24 . While one mechanical door opening system is shown, it is contemplated that the use of any mechanical or electro-mechanical system capable of opening the door, including but not limited to a retractable door made of segments, a drop-down door slidably connected to the sidewall  7  in rails, a magnetic lift system or the like. The thermal breaker  23  is a device calibrated to release the lift bar  19  from its attachment point on the top door  9  if a certain temperature is reached for a certain period of time. Thermal breakers  23  are calibrated to release the door in the event of internal combustion of the cleaning solution  39  or surface chemicals on the cleaning solution  39  within the reservoir  10 . 
         [0026]      FIG. 2  also shows known control command systems used in connection with the novel features of this disclosure. For example, command bay  17  includes a timer, a temperature detector, activating and deactivating buttons, and programming devices to control the different washing parameters within the reservoir  10 . In some embodiments, a heater (not shown) can be used to increase the temperature of the cleaning solution  39  to increase dilution properties of the cleaning solution  39 . The command bay  17  is preferably used for ordinary controls, including a pump control  25  to regulate the flow of spray  47  within the reservoir  10  or to regulate the flow of cleaning solution  39  out of the directional nozzle  45  to increase or decrease the speed of the drive cylinder  41  via the drive wheel  51 . 
         [0027]    The control bay  21  as shown may include flow valves  15  and air valves  16  associated with a pressure gage to regulate an ultrasound vibration head designed to introduce and maintain vibration waves within the cleaning solution  39  to help dislodge dirt particles that adhere to the surface of the print roller  40 . In another embodiment, the vibration device is a transducer. The control bay  21  also includes a lift lever shown as a joystick with a ball and control buttons to control the vertical displacement of the support table  11 . The control bay  21 , the command bay  17 , and the different connected elements, such as the pump  25  and the command block of the pump  26  as shown in  FIG. 3 , include when needed control valves, flow valves, reductions, transformers, and different smaller mechanical and electrical components generally known in the art. The electrical system in one embodiment as shown is connected to an external power network via a cable  2  having a plug  3 . While the use of an external power supply is shown, it is also contemplated that any means to power the different elements, include the use of an alternate generator or even batteries may be used. 
         [0028]    The washer  1  in a preferred embodiment includes U-shaped tubes  6  attached to the bottom  50  of the reservoir  10  for lifting the washer  1  using forks placed on a handheld forklift or automated forklift (not shown). While one portable means of positioning and transportation is shown, it is contemplated is any system to hold, store, position, or transport the washer  1  may be used. Other structural reinforcements, such as L-shaped bars  20 , are shown at the external edges of the sidewall  7  to reinforce the reservoir  10 . The top edge of the reservoir is also shown in a preferred embodiment having a frame  8  made to hold and protect the upper edge of the sidewall  7  but also to support the top door  9  and create a seal for trapping any potential fumes created by the cleaning solution  39  within the reservoir  10 .  FIG. 1  also shows by way of example back internal reinforcements  13 . It is contemplated that any mechanical structural reinforcement placed inside or outside of the reservoir  10  to maintain structural integrity when the washer  1  is filled or moved may be used. 
         [0029]      FIG. 3  shows a front left perspective view of the printing cylinder washer of  FIG. 2  shown from a different point of view to illustrate the pumping and filtration system according to an embodiment of the present disclosure. The system as shown is designed for high-pressure operation and includes fixed, rigid piping  33 ,  28  connected to the pump  25  and to either the spray bars  46  through a first outlet  29  or a nozzle  45  through a second outlet  30 . The different elements as shown are connected by a series of high-pressure metal hoses  32 ,  31 . A filtering cartridge  27  with a top manual valve  74  can be used to control the flow of cleaning solution  39  from the pump to the second outlet  30  and ultimately the directional nozzle  45 . In one embodiment, the pump  25  is calibrated for a fixed flow of cleaning solution  39  that is fully directed to the spray bars  46  when the manual valve  74  is closed and when no driving force is required on the drive wheel  51 . As the manual valve  74  is opened, the flow of cleaning solution  39  to the spray bars  46  is reduced based on the different elements of the system. One of ordinary skill in the art knows multiple methods that may be implemented to calibrate the flows through the first outlet  29  and the second outlet  30 , including but not limited to manual valves, calibrated diaphragms, automated valves, multiple parallel pumps  25 , different sizes of piping or reduced sections of high pressure hose, etc. 
         [0030]      FIG. 6  is a perspective view of the drive assembly  100  with a printing cylinder  40  according to an embodiment of the present disclosure. It is further contemplated that the assembly includes a frame  43  made of metal tubes and plates. In one embodiment, the different structural elements of the frame  43  are assembled using welds and screws. The frame  43  is also open below the printing cylinder  40  to improve the circulation of the cleaning solution  39  within the reservoir  10 . It is further contemplated, but not shown that a frame  42  with an end support plate  42  that is slidably connected to the bottom frame to adjust the distance between the two printing cylinder supports  54 ,  66  mounted on vertical supports may be used. 
         [0031]    The printing cylinder washer  1  also includes a drive assembly  100  disposed on the support table  11  with a drive wheel  51 , a transmission  53 , a drive cylinder  41 , and a printing cylinder support  54 ,  66 . In another embodiment, the printing cylinder support  54  allows the printing cylinder  40  to press against the drive cylinder  41  by sliding down along the sliding support  54  to an equilibrium position closest to the drive cylinder  41 . In the embodiment, the drive wheel  51  is a paddle wheel for transforming flow movement within the cleaning solution  39  in the reservoir  10  into a rotational driving force at the center of the drive wheel  51 . The drive assembly further includes as part of the overall transmission  53  a first strap  62  and a second strap  61  connected to wheels of different radii on the main shaft of the transmission  53 . In one embodiment, the drive cylinder  41  includes a large wheel  52  operating with the transmission  53  to produce a velocity of rotation of the drive cylinder  41  required for the drive assembly  100 . A transmission  53  may be used to decelerate the rotation of the drive cylinder  41  if the drive flow is too rapid or to accelerate the rotation of the drive cylinder  41  if the drive flow of cleaning solution  39  is insufficient. 
         [0032]    A second flow is directed from the inlet  44  to the directional nozzle  45  such that when the cleaning solution  39  is discharged from the directional nozzle  45  in a stream, the cleaning solution contacts the drive wheel  51  whereby the drive wheel  51  rotates and the transmission imparts rotational movement to the drive cylinder  41  from the drive wheel  51 . The printing cylinder support  54 ,  66  disposes a printing cylinder  40  contiguous to the drive cylinder  41 , wherein the pump  25  circulates the cleaning solution  39  in the reservoir  10  from the inlet  44  to the spray bars  46  such that when the cleaning solution  39  is discharged from the spray bar  46  a flow of the cleaning solution  47  is defined. A series of cylinder supports  54 ,  66  is shown where one of the support  54  is angled allowing for the print roller  40 , when placed on the support  54  to be pushed against the drive cylinder  41 . In one embodiment, a series of small friction tabs  60  placed on the drive cylinder  41  is shown to prevent differential rotation between the drive cylinder  41  and the printing cylinder  40 . In other contemplated embodiments, the drive cylinder  41  includes a brushing media or a friction based media to drive the print roller  40 . What is also contemplated is the use of a biasing means to pull the print roller  40  against the drive cylinder  41  after the print roller  40  is placed on the cylinder supports  54 ,  66 . 
         [0033]    In another contemplated embodiment, the support table  11  is a grate connected to an elevator system (not shown) for raising or lowering the support table  11  and the drive assembly  100  placed upon the grate. In yet another embodiment, the support table  11  is an agitation platform designed to vibrate and agitate a print roller  40  while under immersion. 
         [0034]      FIG. 9  is a block diagram of a method of washing a printing cylinder in a printing cylinder washer as contemplated in one embodiment of the present disclosure. The method includes the successive steps of placing  201  a drive assembly on a support table  11  of a printing cylinder washer  1  having a reservoir  10  defining a volume in which a cleaning solution  39  and the support table  11  are disposed. A printing cylinder  40  to be washed is then placed  202  on the printing cylinder support  54 ,  66 . The directional nozzle  45  is then aligned  203  with the drive wheel  51  and the printing cylinder  40  is placed in the flow of the spray bar  47 . The pump  25  is then initiated  204  to direct the cleaning solution  39  through the spray bar  46  via the first outlet  29  to clean the printing cylinder  40  and to direct the cleaning solution  39  through the directional nozzle  45  via the second outlet  30  to energize the drive wheel  51  and rotate the printing cylinder  40 . In an alternate embodiment, the method further comprises the step of moving  205  the support table  11  as an agitation platform, and in yet another embodiment, the method further comprises the step of creating  206  ultrasonic waves in the cleaning solution  39  to dislodge dirt particles from a surface of the printing cylinder  40 . 
         [0035]    Persons of ordinary skill in the art appreciate that although the teachings of the disclosure have been illustrated in connection with certain embodiments and methods, there is no intent to limit the invention to such embodiments and methods. On the contrary, the intention of this disclosure is to cover all modifications and embodiments failing fairly within the scope the teachings of the disclosure.